Manual Compressor de Ar Principal WP100 - BA - en - 08b

S a u e r
C o m p r e s s o r
Type: WP 100
Operator Manual
• High-pressure Compressor
• 2-stage
• Water-cooled
WP100_BA_Titel_en_08.fm
WP100_BA_Titel_en_08.fm
Edition: 07 / 2008
Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation
Sauer compressor Type Approvals
Zertifikate_en_0.fm
Note!
On this page only a few examples are shown. FurtherType Ap-
provals are available on request.
Genuine Sauer spare parts –
certified safety
M E N
CI
SPE Zertifikate_en_0.fm
Table of Contents
1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Type Approval and Genuine Sauer Spare Parts. . . . . 10
1.5 J.P. SAUER & SOHN Customer Service . . . . . . . . . . 11
1.6 Text Conventions Used in This Operator Manual . . . . 12
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Conditions of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Unauthorised modification. . . . . . . . . . . . . . . . . . . . . . 13
2.3 Safety Information - Warning and Caution . . . . . . . . . 14
2.4 Safety Warnings on the Machine . . . . . . . . . . . . . . . . 15
2.5 Safety and protection devices . . . . . . . . . . . . . . . . . . . 16
2.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Safety requirements for personnel . . . . . . . . . . . . . . . 18
2.9 Personal protective equipment . . . . . . . . . . . . . . . . . . 19
3 Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Displays on the Sauer compressor . . . . . . . . . . . . . . . 26
3.4 Indicators and operating elements on the
compressorcontrol. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Technical Specification . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 P&I Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
WP100_BA_en_08bIVZ.fm
5
5 Transport and Installation . . . . . . . . . . . . . . . . . . . .34
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.2 Storage before Installation . . . . . . . . . . . . . . . . . . . . .35
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.4 Connecting the compressor. . . . . . . . . . . . . . . . . . . . .39
5.5 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.6 Checks to be carried out after installation and
before the first start-up. . . . . . . . . . . . . . . . . . . . . . . . .45
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7 Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . .52
8 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.1 J.P. SAUER & SOHN maintenance service. . . . . . . . . .56
8.2 Safety during maintenance . . . . . . . . . . . . . . . . . . . . .56
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . .57
8.4 Table of torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.5 Checking screwed connections . . . . . . . . . . . . . . . . . .59
8.6 Replacing the air filter cartridge. . . . . . . . . . . . . . . . . .60
8.7 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
8.8 Cleaning the oil strainer. . . . . . . . . . . . . . . . . . . . . . . .62
8.9 Checking the valves . . . . . . . . . . . . . . . . . . . . . . . . . .62
8.10 Replacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
8.11 Draining the cooling water . . . . . . . . . . . . . . . . . . . . . .65
8.12 Replacing piston rings, gudgeon pins and gudgeon
pin bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
8.13 Checking pistons and cylinders . . . . . . . . . . . . . . . . . .68
8.14 Wear limits for cylinder diameters . . . . . . . . . . . . . . . .68
8.15 Checking the coupling . . . . . . . . . . . . . . . . . . . . . . . . .69
8.16 Renewing flexible gear rim . . . . . . . . . . . . . . . . . . . . .70
8.17 Inspecting the condensate separators. . . . . . . . . . . . .71
8.18 Overhauling water drain valves . . . . . . . . . . . . . . . . . .71
8.19 Cleaning particle trap. . . . . . . . . . . . . . . . . . . . . . . . . .72
8.20 Checking zinc protection . . . . . . . . . . . . . . . . . . . . . . .72
8.21 Bursting disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.22 Checking the cooling water pump . . . . . . . . . . . . . . . .73
6
9 Storage, Preservation – “Lay-up” Procedure . . . . . 75
9.1 Safety when storing and removing . . . . . . . . . . . . . . . 75
9.2 Temporary decommissioning . . . . . . . . . . . . . . . . . . . 76
9.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.2 Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11 Spare Parts and Accessories. . . . . . . . . . . . . . . . . . 82
12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.1 Commissioning certificate . . . . . . . . . . . . . . . . . . . . . . 85
12.2 Return of goods and notification of claim . . . . . . . . . . 86
7
WP100_BA_K01_07_en_08b.fm
1 General
1.1 Foreword
This Operator Manual provides installation guidance, safe
operation, maintenance and repair instructions with illustrated
parts breakdown.
The following unique specification for the Sauer compressor can
be found on the nameplate affixed to the compressor:
– Compressor type
– Serial number
– Year of construction:
We recommend you record this information in Chapter 11 “Spare
Parts and Accessories” and always provide this data when
requesting parts and any repair instructions.
1.2 Precautions
Specific We recommend that only authorised and trained personnel
precautions operate and service the Sauer compressor. Such responsible
personnel must be thoroughly familiar with, and frequently
review, the Operator Manual.
These instructions must always be readily available at the
compressor installation.
Copyright The copyright for this Operator Manual remains with J.P. SAUER
& SOHN. These instructions, or parts thereof, shall not be copied,
distributed or made available to third parties. Contravention will
result in prosecution.
8
General
1.3 Warranty and Liability

Sauer can no longer cover warranty, be liable for any claims, if a
failure is attributed to any of the following:
– Use of the machine not as specified
– Substitution of parts not manufactured or approved by Sauer
– Use of spare parts that are not genuine Sauer spare parts
– Operation of the machine with faulty or improperly installed
safety and/or protection devices
– Failure to observe Operator Manual
– Unauthorised modification to the machine or its control system
– Inadequate monitoring of machine parts subject to wear
– Failure to maintain/repair in accordance with Sauer
instructions
– Force majeure
9
1.4 Type Approval and Genuine Sauer Spare Parts
• Type approval for the Sauer compressor is valid under the
condition that parts and components specified and qualified by
J.P. SAUER & SOHN are used. Type approval is provided by
the classification society and the EC Declaration of Conformity
or EC Manufacturer's Declaration. Failure to observe these
requirements may void type approval.
• Only the use of genuine Sauer spare parts will ensure
compliance with these specifications and, therefore, reliable
and safe operation of the Sauer compressors.
• If non-genuine Sauer spare parts are used, we reserve the
right of exclusion from liability for personal injury and material
damage.
• Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown just before the Table of Contents in these
instructions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such an instance please contact our Customer Service.
Note!
Be aware this is a high-pressure compressor, for your own
safety and for reliable compressor operation, only use genuine
Sauer parts.
Correct Incorrect
Only use genuine Sauer spare parts Do not use parts from the
with a certificate! “grey market”!
10
General
1.5 J.P. SAUER & SOHN Customer Service

Should you have any technical questions relating to maintenance
or repair, please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH

Customer Service
P.O. Box 92 13
24157 Kiel, Germany
Phone (international):
Technical information +49 431 39 40 -87
Spare parts orders +49 431 39 40 -86/886
Fax (international): +49 431 39 40 -89
Emergency service (international): +49 172 4 14 63 94
E-mail: [email protected]
Web: www.sauersohn.de
Note!
If you have questions regarding your Sauer compressor, please
specify the compressor model and serial number (see Chapter
11 “Spare Parts and Accessories” or nameplate on the
compressor).
11
1.6 Text Conventions Used in This Operator Manual
Lists General lists are marked using a dash.
Example:
Compressor cooling consists of
– Cooler assembly
– Cooling water lines
Instructions Individual instructions or multiple instructions requiring action but

where the sequence is of no importance are normally denoted by
a bullet-point.
Example:
• Check oil level.
Instructions to be carried out in a certain sequence are

numbered.
Example:
1. Turn the main switch ON.
2. Choose the operating mode.
3. Turn the control ON.
Results of actions carried out are denoted by a tick mark.

Example:
The control light is on.
Safetyinstruc- Safety and warning instructions are presented pictorially with

tions clear instructions. The safety instructions are described in detail
in Chapter 2 “Safety”. WP100_BA_K01_07_en_08b.fm
12
Safety
2 Safety
2.1 Conditions of Use
This Sauer compressor must be used for the compression of air
only. The Sauer compressor must not be used at ambient
temperatures below +5 °C. Any other unauthorised use requires
the express written approval of J.P. SAUER & SOHN.
In addition, specified conditions of use also include observing the
Operator Manual and the installation requirements and
maintenance intervals described there.
Most accidents which occur during operation and maintenance of
machinery result from failure to observe basic safety rules or
precautions.
When handling, operating or carrying out maintenance,
personnel must observe safe engineering working practices and
local regulations.
2.2 Unauthorised modification

Unauthorised modification of the Sauer compressor is not
permitted. Modifications may lead to an accident that can be life-
threatening, cause personal injury or result in damage to the
equipment.
Contact J.P. SAUER & SOHN when planning any modification to
obtain written approval.
13
2.3 Safety Information - Warning and Caution
The safety information in these instructions is presented as ‘high’
risk and ‘lower’ risk, as follows:
Warning - Danger!
High risk.
Ignoring these safety instructions can cause personal injury, or
death, and significant equipment damage.
Caution - Note!
Less risk.
Disregarding this safety note may cause damage to the
equipment.
14
Safety
2.4 Safety Warnings on the Machine

Danger!
Safety labelling affixed to the machine must not be altered or
removed. Replace damaged or lost safety labels immediately
with an approved replacement.
The Sauer compressor with an EC Manufacturer's Declaration or

EC Declaration of Conformity is marked with the following safety
labelling:
Safety label Meaning Safety label Meaning
High voltage! Danger Read Operator

to life! Manual!
Compressor starts
Wear hearing
automatically without
protection!
warning!
Rotational direction of
Hot surface!
crankshaft
Location of safety markings

15
2.5 Safety and protection devices
Danger!
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked:
Safety valves must only be
installed with a lock-seal and
replaced, adjusted and re-sealed by authorised personnel.
Safety valves Each compression stage of the Sauer compressor is equipped

with a safety valve, which will fully discharge air when the blow-
off pressure is reached.
Safety valves are installed at the following locations:
– 1st compression stage: at the front of the cooler cover of the
1st stage;
– 2nd compression stage: at the final separator after the
2nd stage.
High air tempera- The Sauer compressor is equipped with a temperature sensor.
ture switch The high air temperature switch shuts down the compressor if the
compressed air temperature exceeds the limit value.
16
Safety
2.6 Noise protection

Sound pressure level details are found in the Technical
Specification (see Chapter 4).
The Sauer compressor can be equipped with a sound-
dampening enclosure to reduce noise, available as an accessory
from J.P. SAUER & SOHN.
Danger!
When the compressor is operated without sound-dampening
enclosure, hearing protection should be worn when working
near the compressor.
2.7 Waste disposal

Note!
The following materials which accumulate during operation of
the compressor must be disposed of in an environmentally
sound manner in accordance with applicable laws:
– Condensate (oil/water) arising from inter-cooling in the
compression process
– Used oil and grease, and used oil and grease and materials
soiled by such lubricants
– Cleaning agents and rags soiled by such agents
17
2.8 Safety requirements for personnel
Only personnel authorised by J.P. SAUER & SOHN are permitted
to service the Sauer compressor! Before commencing work they
must have read and understood the instructions in the Operator
Manual, and must be familiar with all safety devices and safety
regulations.
In addition to the instructions in this Operator Manual and
supplier documentation, accepted engineering standards must
be observed as well as all local laws, standards and regulations
such as
– The Equipment and Product Safety Act,
– The regulations for industrial safety,
– The regulations for accident prevention pertaining to
compressors,
– Provision of the Verband Deutscher Elektrotechniker (VDE/
German electrical engineering industry association)
– Regulations on environmental protection.
Additionally, where appropriate classification society and
operational regulations must be observed.
Only those trained and thoroughly familiar with the compressor
operation should be authorised to operate the compressor.
Personnel authorised to service the compressor must be trained
technical specialists of the owner and manufacturer.
18
Safety
2.9 Personal protective equipment

The owner should provide personal protection equipment (e.g.
hearing protection, safety boots, etc.) for personnel carrying out
any work on the Sauer compressor.
19
3 Design and Function
3.1 Overview
Note!
Details of parts and spare parts can be found in the spare parts
catalogue.
Cooling water Cooling water

Inlet 5 Outlet 3 13
1
2
12
8 6 9
4
10
20
Design and Function
Item Designation
1 Cylinder 1st and 2nd stage
2 Safety valve 1st stage
3 Safety valve 2nd stage
4 Air filter
5 Oil fill pipe
6 Oil dipstick
7 Sump oil drain
8 Drain valve 1st stage
9 Drain valve 2nd stage
10 Compressed air temperature sensor
11 Cooling water stop valve
12 Crankcase vent
13 Motor
21
Vertical
sectional view
1st stage 2nd stage
10 11
12
8 13
7
4
5
1 6 2
22
Design and Function
Item Designation
1 Crankcase
2 Crankshaft
3 Flywheel
4 Coupling
5 Connecting rod 1st stage
6 Connecting rod 2nd stage
7 Cylinder 1st and 2nd stage
8 Piston 1st stage
9 Piston 2nd stage
10 Valve cover 1st stage
11 Valve cover 2nd stage
12 Lamellar valve 1st stage
13 Concentric valve 2nd stage
23
3.2 Functional description
Drive The Sauer Compressor is driven by an electric motor flange-
mounted to the crankcase bell-housing. The power is transmitted
by means of a flexible coupling.
Compressor Driven by an AC motor drive, the Sauer compressor is controlled

control and monitored by an electrical compressor control. This control
system must comply with legal regulations. Optionally,
J.P. SAUER & SOHN supplies a suitable compressor control.
Compression The compressor takes in the ambient air via a layered filter with
a tube silencer and compresses it in two compression stages with
a total of two single-stage cylinders to the final pressure. The
cylinders are mounted in a row in a common cylinder housing.
Each cylinder is a compression stage, after which the air is inter-
cooled. A replaceable wet liner with a double O-ring gasket is
installed in each cylinder.
The cylinders are equipped with concentric valves and with
lamellar valves which are easy to maintain and have a long
service life.
Cooling The compressor is cooled with fresh water. Cooling with sea
water is available as an option.
Inter-cooling of the compressed air in the 1st and 2nd stage takes
place in the straight cooling pipes which are embedded in the
cylinder housing and evenly surrounded by cooling water.
1st stage 2nd stage
Cooler pipe
Cylinder housing
24
Design and Function
The cooling pipe and the replaceable liners are directly immersed
in cooling water in the cylinder. The cooling water spaces are
protected by zinc anodes against corrosion. When at a complete
standstill, the cooling water supply is interrupted by a solenoid
valve at the cooling water inlet.
The compressor cooling is monitored by a temperature sensor.
The compressor is immediately stopped if the compressed air
temperature exceeds the upper limit value.
Optionally, the compressor can be fitted with a cooling water
pump driven by its own electric motor.
Condensate Oil/water condensate that collects during compression and inter-

separation cooling is collected in a separate condensate separator behind
the 1st and 2nd stage.
Separator Separator
1st stage 2nd stage
Oil/water Condensate is drained via drain lines. There are solenoid valves
draining and installed in the drain lines. The drain valves must be open when
the Sauer compressor is unpressurised. A few seconds after
pressure relief
starting, the drain valves should close and the compressor
should power up against system pressure. The drain valves
should drain the system during operation at preset intervals. The
control of the drain valves (solenoid valves) is carried out by the
compressor control.
Lubrication The drive is lubricated by oil splash or mist in the crankcase. For
this purpose, there are lubricating pins located on both
connecting rods which dip into the oil pan and fling the lubricating
oil against the lubricating points.
25
3.3 Displays on the Sauer compressor
1 5 4
3
2
Item Designation Display

1 Pressure gauge 1st stage Compressed air pressure after 1st stage
2 Pressure gauge 2nd stage Compressed air pressure after 2nd stage
3 Thermometer 1st stage Compressed air temperature after 1st stage
4 Thermometer 2nd stage Compressed air temperature after 2nd stage
5 Cooling water thermometer Temperature of cooling water
26
Design and Function
3.4 Indicators and operating elements on the

compressorcontrol
Note!
If the compressor control is supplied by J.P. SAUER & SOHN,
read the documentation supplied.
On the front of the compressor control, the following indicators

and control features can be found:
Display/
Explanation
Operating element
Signal lamp
Illuminates when the compressor is running.
“Operation”
Fault indicator lamp Illuminates if the compressor has shut down because of lack of
“Oil level” (option) oil.
Fault indicator lamp Illuminates if the compressor has shut down because of high
“Air temperature” outlet gas temperature.
Fault indicator lamp Illuminates if the compressor has shut down because of excess
“Overcurrent” motor current.
Run time counter Indicates the hours the compressor has run.
“Manual” mode:
Starts the compressor manually. The compressor starts up and
continues to run until it is manually turned off again.
Selector position “0”:
Operation mode Turn the compressor off manually. Any pending fault messages
selector are reset.
“Auto” mode:
The compressor starts and stops with the opening and closing
of a remote contact (e.g. pressure switch at a compressed air
vessel).
Disconnects the power supply from the compressor control to
the compressor.
Main switch
A main isolator switch should be installed if required by local
law and regulations.
27
4 Technical Specification
4.1 Specification data
Designation Data
Compressor type WP 100
Number of cylinders 2
Number of compression stages 2
Cylinder diameter 1st stage 136 mm
Cylinder diameter 2nd stage 60 mm
Piston stroke 94 mm
Maximum speed 1800 rpm
Direction of rotation (when looking toward Clockwise
flywheel)
Maximum working pressure 30 bar
Set pressures for safety valves:

1st stage 8 bar
2nd stage 5% above final pressure
Oil sump capacity 9l

Oil refill quantity – dipstick MAX/MIN 2.5 l
Oil type See Chapter 10 “Lubricant Table”
Oil level switch (option):

Holding power 10 VA
Operating current 0.5 A

Setting Opens when oil level falls
Switch function Change-over contact
28
Technical Specification
Designation Data
Drain valves
Pickup and holding power 18 VA/14 W
Setting Currentless open
Relief starting: approx. 15 sec
Periodic automatic drainage: every 15
min for 15 s
Final pressure sensor (option):

Maximum switching current 6 A/220 V
Setting As required by customer
Temperature switch:
Maximum switching current 16 A/440 V
Setting Opens at 80 °C rising
Maximum permissible entry pressure at 5 bar without cooling water pump

the 3 bar with cooling water pump
cooling water inlet
Bursting pressure of the burst disc > 6 bar
in the cooling water system:
Cooling water temperature at the outlet 40 to 50 °C
Cooling water stop valve Holding power: 36 W
Valve is currentless closed
Cooling water pump (option):
Electrical connection 440 V/60 Hz 1.1 kW or 400 V/50 Hz 1 kW
Setting Not self-priming,
should start and stop in synchronisation
with the compressor
29
Designation Data
Sound pressure level max. 89 dB(A)
free field at 1 m
Weight and dimensions See installation drawing
Note!
Please refer to the order-specific documentation of your
compressor for data such as final pressure, speed, power
requirements, etc.
30
31
4.2 P&I Flow Diagram
Cooling water 22
outlet 7 9 11 23
3 4 21 20 19 M Cooling water
inlet
17
M 1 2 8 10 12 18
1 2 Compressed air outlet
16
15
5 6
Air intake
13 14
Condensate
M Drive Solenoid valve Suction filter

motor
Compressor Safety valve Inter-,

stage post-cooler
Non-return valve
Separator
Pump Temperature
switch
Temperature
Pressure gauge
Oil level
switch
32
Item Designation
1 1st compression stage
2 2nd compression stage
3 Cooler 1st stage
4 Cooler 2nd stage
5 Separator 1st stage
6 Separator 2nd stage
7 Safety valve 1st stage
8 Safety valve 2nd stage
9 Pressure gauge 1st stage
10 Pressure gauge 2nd stage
11 Thermometer 1st stage
12 Thermometer 2nd stage
13 Solenoid valve (drainage) 1st stage
14 Solenoid valve (drainage) 2nd stage
15 Intake air filter
16 Oil level switch (option)
17 Drive motor
18 Cooling water pump (option)
Cooling water manual valve
19
(only with optional cooling water pump)
20 Cooling water particle trap
21 Cooling water stop valve
22 Cooling water thermometer
23 Motor cooling water pump
33
5 Transport and Installation
5.1 Transport
Shipping The machine is packed ready for shipping.
• The Sauer compressor must be checked for completeness
and any damage immediately upon receipt.
• Damage to the packaging or the machine should be reported
to the transport firm and J.P. SAUER & SOHN immediately.
Transport The Sauer compressor must be transported using a forklift truck

or be hoisted by a crane.
Danger!
Suspended load during transport.
The forklift truck/crane must have sufficient load-bearing
capacity.
Ensure that no personnel are within the danger area of the
suspended load and the forklift truck/crane.
Sling the unpacked compressor using the four lifting eye bolts
(see illustration).
Raise, move into position and set down with care.
Lifting eye bolt

34
Transport and Installation
5.2 Storage before Installation

If the Sauer compressor has to be stored before installation, do
not unpack, and store under the following conditions:
– Temperature: +5 to +40 °C;
– Relative humidity 30 to 95%, non-condensing
– In a dry area, under a roof and protected from the weather
– Protected from being soiled
– Protected against vibration and shock
Note!
The standard factory protective packing is sufficient for a
maximum storage period of 12 months.
Note!
High pressure hoses can be stored for up to two years after
delivery.
35
5.3 Installation
Note!
If in doubt regarding the suitability of the intended installation
area, please contact J.P. SAUER & SOHN. If required for the
installation area, Sauer can provide help with the design of a
ventilation system.
For proper installation follow the installation instructions and

observe the following.
Installation – The installation area must be dry and free from dust.
requirements – Ensure that the installation is ventilated in such a way that the
heat generated during operation is removed.
– Room temperature during operation of the Sauer compressor:
max. 55 °C
+5 °C to +55 °C
(Please contact J.P. SAUER & SOHN for operation outside
this temperature range).
– For proper installation, follow the installation instructions and
min. 5 °C observe the following conditions.
Note!
The air temperature at the location where the compressor is
installed must not exceed +55 °C. Conditions in the area of
installation as well as the heat generated by the compressor and
any other machines installed in the same area must be kept in
mind.
If necessary, install a ventilation or air extraction system in the
area.
Install the fresh air feed in such a way that the cooling air stream
is never directed at the compressor. Otherwise, there is a danger
that condensation will occur within the machine, with
corresponding consequential damage.
36
Correct ventilation Incorrect ventilation
– At room temperatures below +5 °C the room must be heated

or a heater must be installed on the Sauer compressor.
– The installation location must be selected in such a way that
the Sauer compressor is easily accessible.
The cooling water spaces are automatically kept vented through

the arrangement of the cooling water inlet and outlet.
The quantity of cooling water must be set at a level such that the
cooling water outlet temperature is between 40 °C and 50 °C. A
maximum cooling water outlet temperature of 50 °C must not be
exceeded.
50 °C
40 °C
Note!
The Sauer compressor is cooled with fresh water.
Seawater can be used for cooling if desired, but according to its

temperature and chemical composition seawater can be very
corrosive.
37
Note!
J.P. SAUER & SOHN would be pleased to advise you on
installation of the compressors.
Foundation
Note!
The standard delivery anti-vibration mount has a resonant
frequency of approx. 10 Hz.
Excitation of the compressor foundation by vibrations from other
machines installed in the vicinity must not be in the 10 Hz range.
Otherwise there is a danger that the standard anti-vibration
mount could be destroyed by resonating vibration.
1. Check whether there are vibrations of the machine
foundation in the 10 Hz range.
2. If in doubt, contact J.P. SAUER & SOHN in order to clarify
whether a different anti-vibration mount can be used.
38
5.4 Connecting the compressor
Danger!
The compressor should only be connected by a qualified
technician. Any work on the electrical installation must be carried
out by qualified electricians only.
Pipelines Compressed air outlet, cooling water inlet and outlet, and
drainage connections of the Sauer compressor must be
connected by hose connections to any of the system owner’s
permanent piping.
Cooling water Cooling water

Inlet Outlet
Compressed air
Condensate
Danger!
At the compressor start-up and during drainage compressed air
escapes from the drainage connections. Consequently, do not
operate the compressor without hose lines connected.
39
The hose lines must be installed free of tension and not twisted.
Correct installation Incorrect installation
Drainage
Note!
Accumulated condensate contains oil. It may only be disposed
of in compliance with applicable legal regulations.
J.P. SAUER & SOHN offers condensate collection containers for
separating air from condensate as well as condensate
processing systems for separating oil from condensate.
Note!
We recommend connecting up the compressor drainage
separately.
If you wish to combine the drainage of several compressors,
please observe the following:
Choose a sufficient nominal diameter for the common drainage
line;
Connect the drainage lines of the individual compressors at a
sharp angle to the common drainage line, so that no pressure
can build up in the drainage line of a compressor that is not in
operation.
40
Correct connection Incorrect connection

41
Connections The illustration below shows the connections and the fittings for
the operation of a typical Sauer compressor.
8 6 1 2 3 4
Item Designation Type Function

1 Drive motor AC motor Compressor drive
2 Non-return valve Plate valve Prevent air flowing back
3 Final pressure Change-over Start/stop control for the compressor
switch switch
4 Safety valve Spring-loaded To limit excessive pressure on the
safety valve parts subjected to pressure
5 Drainage valve Solenoid valve Start relief and drainage
6 High air tempera- Change-over Switch off compressor if temperature
ture switch switch is too high
7 Oil level switch Change-over Switch off the compressor if oil
(option) switch pressure is too low
8 Cooling water Solenoid valve Prevent flow of cooling water when
stop valve machine is not operating
9 Cooling water Centrifugal pump, Circulate cooling water
pump (option) not self-priming
42
Note!
For technical specifications of the individual items, please refer
to Chapter 4.
All change-over switches are factory adjusted.
If desired, the components are supplied pre-wired to a terminal
box.
43
5.5 Filling with oil
The Sauer compressor is delivered without oil.
Oil fill cap
Dipstick
Danger!
Make sure to fill the crankcase of the compressor with oil before
initial operation!
Use an appropriate lubricating oil (see Chapter 10 “Lubricant
Table”).
Note the amount of oil needed (see Chapter 4 “Technical
Specification”).
1. Unscrew the oil fill cap (red).

2. Pour in oil and check the oil level with the dipstick (red).
Note!
Only fill with oil up to the upper level gauge mark on dipstick.
Overfilling increases the oil consumption of the compressor.
3. Replace the dipstick and screw the oil fill cap back in.
44
5.6 Checks to be carried out after installation and

before the first start-up.
– Check that the electricity connection matches the data on the
nameplate.
– Check that all connections between the compressor and the
compressed air equipment are properly installed.
Pay particular attention to the compressed air connection.
– Are the drainage lines properly connected?
– Are the cooling water lines open?
– Has the crankcase been filled with oil?
– Have all tools and foreign objects been removed from the
compressor?
– Is the entire unit clean?
45
6 Operation
6.1 Safe operation
Danger!
Only authorised persons are permitted to put the Sauer
compressor into operation and operate it!
Danger!
Only switch on and start the compressor when
it has been checked that it is in perfect condition;
all tools and foreign objects have been removed from the
machine.
Danger!
Immediately turn compressor off if personnel and property are
endangered. Only re-start compressor when there is no more
danger or possible damage.
Danger!
In Automatic mode the compressor starts automatically without
warning.
Danger!
Risk of burns from touching hot surfaces of the compressor
during operation. Wear protective gloves.
Danger!
Risk of hearing damage because of the sound pressure level
while the compressor is running! Wear hearing protection near
the compressor.
Note!
Switch compressor off in the event of any abnormal/fault
conditions or unexpected events. Eliminate the cause of the
problem with the help of Chapter 7 “Troubleshooting.”
46
Operation
6.2 Operating modes

After you have turned on the power supply to the Sauer
compressor, it can be started with one of the following two
operating modes using the mode selector switch:
– “Manual” operating mode:
The compressor starts and continues to run until it is stopped
or turned off either by using the mode selector switch or the
main switch.
– “Automatic” operating mode:
Starting and stopping the compressor is controlled by external
devices (for example using the pressure switch of the pressure
vessel).
When the Sauer compressor starts, it starts without load with the
drainage valves open. After a few seconds the valves close and
the compressor powers up against system pressure.
47
6.3 Initial operation
Check the Allow the Sauer compressor to run only for a few seconds to
direction of check the direction of rotation.
rotation 1. Switch the power supply on.
2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
3. Immediately check the compressor’s direction of rotation. It
must rotate in the direction indicated by the arrow on the
crankcase.
4. Set the mode selector switch to “0” to stop the compressor.
5. Switch off the power supply.
6. If the direction of rotation is incorrect, the polarity of the
electric motor should be changed by a qualified electrician.
Danger!
If the crank shaft rotates in the wrong direction, no oil pressure
builds up. Risk of subsequent damage.
7. Checking the direction of rotation of the cooling water pump

(option):
Switch on the pump motor.
The motor must not be allowed to reach its operating speed.
The direction of rotation must agree with the rotation direction
arrow on the pump. If the direction of rotation is incorrect, the
polarity of the electric motor should be changed by a qualified
electrician.
Pump and suction pipe must be completely filled with cooling
water.
Danger!
The cooling water pump must not be allowed to run dry.
48
Operation
Test run 1. Switch the power supply on.

2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
If correctly adjusted, the drain valves close after about 15
seconds and the compressor should power up against
system pressure.
3. Check the pressure gauges of each stage and compare
readings with the nominal values (see Chapter 6.4 “Routine
Operation”).
4. Check the function of the automatic periodic drainage.
It must drain for about 15 seconds every 15 minutes. This is
indicated by a drop in pressure on the pressure gauge.
5. Check that cooling water is flowing.
The temperature of the cooling water at the outlet must stay
within the range given in the “Specification data table” in
Chapter 4.1. The temperature can be read from the cooling
water thermometer at the cooling water outlet. If these
temperatures are exceeded or not reached the flow of cooling
water must be increased or decreased accordingly.
In the case of machines with an integrated cooling water
pump, the flow rate can be regulated with the slide on the
pump.
6. Set the mode selector switch to “0” to stop the compressor.
7. Switch off the power supply.
8. If necessary eliminate the cause of deviations from nominal
values and malfunctions. See also Chapter 7
“Troubleshooting”.
9. Complete the commissioning certificate and send it to
J.P. SAUER & SOHN Customer Service. The commissioning
certificate is in the Appendix.
49
6.4 Routine operation
Cleaning • Keep compressor area clean.
• Keep indicators and control elements clean.
Checks • Inspect connections, pipes and electric cables for damage.

• Check the oil level once a week before starting, top up, if
necessary. Do not overfill with oil beyond the maximum mark.
Operation 1. Switch the power supply on.

2. Open the cooling water lines.
3. Set mode selector switch to “Auto“ to operate the compressor
in Automatic mode.
Watch out for • Abnormal operating noise.

• Pay attention to leaks (compressed air, oil, condensate). The
temperature of the cooling water at the outlet must stay within
the range given in the “Specification data table” in Chapter 4.1.
• The pressure indicated on the pressure gauge must remain
within the grey zone in the stage pressure diagram (see
below).
In the event of deviations, see Chapter 7 “Troubleshooting”.
50
Operation
Stage pressure diagram 1st stage
2nd stage [bar]

30
20
10
1 2 3 4 5 6
1st stage [bar]
Note!
Depending on the desired final pressure in the 2nd stage, the
allowable pressure for the 1st stage can be read from the above
diagram.
51
7 Troubleshooting guide
Note!
Should a malfunction occur, first check the indicators on the
compressor control panel and on the compressor.
Try to correct the fault with the help of the table below.
If the fault cannot be corrected, please contact J.P. SAUER &
SOHN Customer Service. The fault description journal is in the
Appendix of this Operator Manual.
Probable
Fault Remedy
cause
Compressor does not No input power supply/no Check the fuses. Replace blown
start or switches off. control voltage. fuses.
Check oil level and top up if neces-
Oil level too low.
sary. Check for leaks.
Fill with recommended oil.
Oil too viscous. Check that room temperature is
Compressor was > + 5 °C.
switched off because the
oil level switch tripped. Oil filter blocked. Clean the oil filter.
Oil pipe blocked. Clean oil pipe.
Check oil pump. If necessary elimi-
Oil pump faulty or leaking.
nate leak or replace oil pump.
Check supply voltage and electrical
connections. The compressor can
be started again after a cooling
down period.
Compressor was Excessive current drawn. Check whether the crankshaft can
switched off by overcur- easily be turned by hand. If not, dis-
rent relay. connect and ascertain whether the
problem has to do with the motor or

the compressor.
Check cylinders and pistons for any
Piston seizure
score marks, replace as necessary.
52
Troubleshooting guide
Probable
Fault Remedy
cause
Safety valve of 1st stage

blows off:
Pressure exceeds
blow-off pressure (8 2nd stage valve is not work- Check the valve of the 2nd stage
bar) ing properly. and replace if necessary.
Gasket between suction

and pressure side of the 2nd Replace gasket.
stage is faulty.
Pressure below blow-
Safety valve is faulty. Replace safety valve.
off pressure (8 bar)
Safety valve of 2nd stage

blows off:
Valve in the air line to the
compressed air vessel is Open valve.
closed.
Pressure above blow-
Pressure switch is set too
off pressure (final Lower the pressure setting.
high.
pressure + 5%)
Excessively high pressure
losses in the air line to the Reduce the pressure losses.
compressed air vessel.
Pressure below blow-
Safety valve is set too low
off pressure (final Replace safety valve.
or is faulty.
pressure +5%).
Pressure gauge of the 1st Check the valve of the 2nd stage
Valve of the 2nd stage is
stage is showing exces- and replace if necessary. Replace
leaking.
sive pressure. gaskets.
Valve of the 1st stage is Check the valve of the 1st stage
Pressure gauge of the leaking. and replace if necessary.
1st stage is showing
insufficient pressure. Clean the air filter insert or replace
Air filter very dirty.
it.
No power at solenoid drain- Check solenoid valve power sup-
The pressure gauges of age valve. ply.
all stages show no pres-
sure. Solenoid valve of the drain- Check the solenoid valve and
age is faulty. replace it if necessary.
53
Probable
Fault Remedy
cause
Connection gaskets or
Replace faulty gasket or seal.
seals leaking.
Air escaping from the Switch compressor off. Wait until all
compressed air lines. parts are no longer under pressure;
Cutting rings leaking.
check the pressure gauge for this.
Tighten all fittings.
Increase flow of cooling water
(in the case of a cooling water
pump only: Open the slide at the
Compressed air tempera-
rear of the pump further);
ture at the outlet too high as
Check the temperature of the cool-
a result of shortage of cool-
ing water at the outlet and the func-
ing water.
Compressor was tioning of the cooling water stop
switched off, tempera- valve;
ture switch has tripped. Clean the particle trap
Compressed air tempera-
ture at the outlet too high
Clean the cooling water containers
because of poor thermal
with a suitable, environmentally
transition in the cooler as a
compatible agent.
result of scaling in the
chamber.
No power supply.
Check fuses, replace blown fuses.
Solenoid valve (drainage)
Solenoid faulty. Replace solenoid.
does not close.
Foreign matter in solenoid
Replace solenoid valve.
valve.
No power supply. Check fuses, replace blown fuses.
Cooling water stop valve Solenoid faulty. Replace solenoid.
does not open.
Foreign matter in solenoid
Replace solenoid valve.
valve.
Check connecting rod bearing,
Connecting rod bearing
replace if necessary.
faulty.
Check oil supply.
Check gudgeon pin bearing,
Abnormal compressor Gudgeon pin bearing faulty.
replace if necessary.
noise.
Check crank shaft bearing, replace
Crankshaft bearing faulty.

if necessary.
Check motor bearing, replace if
Motor bearing faulty.
necessary.
54
Troubleshooting guide
Probable
Fault Remedy
cause
Tighten all screws.
If there is significant leakage
check to see which gasket is faulty,
Oil leaking from crank- Gasket or shaft then replace it.
case. seal faulty. Screws not tight. Minor traces of oil on the crank-
case or oil drops below the com-
pressor are harmless. Wipe off with
a lint-free rag.
Water escaping at the
O-ring of the liner is faulty
relief groove of the cylin- Replace O-ring.
above the relief groove.
der flange surface.
Oil escaping at the relief
O-ring of the liner is faulty
groove of the cylinder Replace O-ring.
below the relief groove.
flange surface.
Excessive cooling of com-
pressor due to
Reduce flow of cooling water.
- Flow of cooling water too
Change room ventilation so that air
high
stream is not blown directly against
- Unfavourable room venti-
Water in the oil compressor.
lation
Extend compressor running time
- Very short compressor
running time
Check drainage lines and drainage
Poor drainage.
intervals.
Leaks in cooler. Replace cooler insert.
Burst disc in the cooling Determine the cause of the pres-
water circuit triggers Pressure peaks in the cool-
sure peaks and eliminate these
OR ing water circuit cause the
causes (startup of additional
Cooling water safety burst disc bursting pressure
pumps, actuation of electromag-
valve triggers. or the safety valve preset
netic stop valves or shuttle valves,
pressure to be exceeded.
or similar causes)
Check drainage lines and drainage
intervals.
Premature fracture of
valve plates or valve Poor drainage.
Note:Indentations in the gasket
springs
contact surface of the valve plate
are normal.
55
8
8 Maintenance
8.1 J.P. SAUER & SOHN maintenance service
J.P. SAUER & SOHN customer service offers various
maintenance services: inspections, maintenance, major
overhauls, reconditioned compressors and service contracts.
8.2 Safety during maintenance

Before 1. Interrupt power supply to the compressor.
maintenance 2. Fit 'Warning: maintenance work' warning sign to power
work supply.
3. Shut off the compressor and secure to prevent restarting.
Danger!
Risk of injury due to incorrect operation!
Only authorised personnel are permitted to service and adjust
the Sauer compressor!
Danger!
Risk of injury from hot surfaces!
Let compressor cool down after turning OFF.
Danger!
Risk of injury due to pressurised components!
Before undertaking any maintenance work, use pressure gauge
to ensure that there is no more pressure in the compressor.
Danger!
Danger! High voltage!
– Never assume that a circuit is de-energised – always check
for your own safety!
– The mains isolator remains energised, even when it is turned
OFF.
– Components being worked on should only be energised if this
is explicitly specified.
Danger!
Danger of death if there are no safety devices or no isolating
protection devices!
After undertaking servicing work, always refit all safety devices
I_WA006_4.fm
and isolating protection devices. This also applies to electrical

protection devices.
56
Maintenance
8.3 Maintenance schedule

Danger!
Whenever undertaking maintenance work, observe section 8.4,
'Table of tightening torques', for particular bolts.
Note!
The maintenance intervals specified in the maintenance
schedule must be observed. Shortening the maintenance
intervals is of no advantage with regard to the operating
performance or service life of the Sauer compressor.
Note!
After the final maintenance routine, the maintenance schedule
starts from the beginning.
Use of the • Use the maintenance schedule as a master template or copy

maintenance the relevant page from the digital document and save it as a
separate file under a suitable name. Use the maintenance
schedule
schedule as a guide and for verification.
• Regularly check the maintenance schedule to see which
maintenance intervals are due depending upon the number of
operating hours. The intervals are shown in the table's column
headers.
• Check the column for each maintenance interval to see which
maintenance work is to be carried out at the end of the
maintenance interval. The required tasks are indicated by
checkboxes. A description and the section number of the tasks
are shown in the first column.
• Carry out all maintenance tasks for a maintenance interval
and tick the appropriate check boxes of the maintenance
schedule. Then enter hours of operation, date and signature.
• When beginning a new maintenance schedule:
– enter: maintenance schedule number, date and hours of
operation, main specifications and date of commissioning;
– mark with a cross: beginning of this maintenance
schedule following commissioning or following the last
maintenance routine.
I_WA006_4.fm
57
Maintenance Schedule No. Compressor type: WP100
Beginning of this maintenance schedule: Type series 2W
❑ after commissioning Compressor number:
❑ after last maintenance routine Factory no.:

Date: Year of construction:
Hours of operation: Date of commissioning:
Interval
last maintenance routine

[hours of operation]
At least annually
commissioning
at < 1000 h
50 h after
50 h after
2000 h
1000 h
3000 h
4000 h
Maintenance work
069222
069223
069222
069224
Maintenance set item no.
Check screwed connections, section 8.5 ❏ ❏

Replace air filter cartridge, section 8.6 ❏ ❏ ❏ ❏ ❏
Carry out oil change, section 8.7 ❏ ❏ ❏ ❏ ❏ ❏ ❏
Clean oil strainer, section 8.8 ❏
Check 1st-stage valves, section 8.9 ❏ ❏
Replace 1st-stage valves, section 8.10 ❏ ❏
Replace 2nd-stage valves, section 8.10 ❏ ❏ ❏ ❏
Replace 1st-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 8.12
Replace 2nd-stage piston rings, gudgeon pins and ❏
gudgeon pin bearings, section 8.12
Check piston and cylinder, section 8.13 ❏
Renew flexible gear rim, section 8.16 ❏
Check condensate separator, section 8.17 ❏
Overhaul drain valves ❏
(as per order), section 8.18
Clean particle trap, section 8.19 ❏ ❏ ❏ ❏
Replace zinc protection ❏
(freshwater operation), section 8.20
Replace bursting disc, section 8.21 ❏ ❏ ❏ ❏
Check cooling water pump, section 8.22
I_WA006_4.fm
Hours of operation
Date
Signature (initials)
58
Maintenance
8.4 Table of torques
Screw(s) Torque
Connecting rod screws 70 Nm
Flywheel fastening screw 175 Nm
Valve cover screws (1st/2nd stage) 82 Nm
Bursting disc flange 54 Nm
Valve cover retaining screw for valve of 1st

15 Nm
stage
8.5 Checking screwed connections

Check all unions and screwed connections for tightness and re-
tighten if necessary. This relates to:
– cooler and air lines;
– unions on pipe and hose lines;
– cylinder heads;
– cylinders;
– electric motor;
– measuring and switching devices;
– bearing; and
– accessories and equipment parts.
I_WA006_4.fm
59
8.6 Replacing the air filter cartridge
Wing nut Cap
1. Remove the wing nuts and take the air filter cap off.
2. Remove used cartridge.
3. Clean filter housing with a suitable solvent and wipe out with
a lint-free cloth.
4. Insert new cartridge into air filter.
5. Place cap back and tighten the wing nuts.
I_WA006_4.fm
60
Maintenance
8.7 Changing the oil

l
Note!
Use oil according to the lubricant table (see section 10).
Oil filler cap
Dipstick
Oil drain valve cap
1. Run compressor for approx. 15 minutes until operating

temperature is reached.
2. Place drip tray (of a capacity sufficient to hold the complete
oil filling quantity, 9.0 l) below the oil drain valve.
3. Unscrew oil filler cap and oil drain valve cap, open oil drain
valve and pull out dipstick.
4. Wait until all oil is drained.
I_WA006_4.fm
5. Close oil drain valve and screw on cap.
61
6. Top up oil and check level with the dipstick.
✓ The level should be between the upper and lower marks on
the dipstick.
7. Put dipstick back in and screw oil filler cap back on.
8.8 Cleaning the oil strainer

1. Unscrew nuts on inspection hole cover.
2. Take off inspection hole cover.
3. Unscrew union on oil strainer.
4. Take out oil strainer.
5. Wash out oil strainer in a suitable solvent.
6. Carefully clean sealing surface for inspection hole cover
gasket.
7. Position inspection hole cover with new original Sauer
gasket.
8. Tightly refasten oil strainer.
9. Tighten nuts on inspection hole cover.
8.9 Checking the valves

Removing valves 1. Loosen clamp on air filter and take out air filter.
2. Loosen unions and hose lines at the valve covers.
3. Undo valve cover screws and take off valve covers. Prise off
using the screws if necessary.
4. Carefully take out 1st-stage valve.
5. Undo valve retaining screw and take out 2nd-stage valve.
Note!
When removing and installing a valve, take care that no valve
parts are damaged. This particularly applies to the sealing
surfaces.
Checking valves 1. Check valves externally for:

damage,
carbonisation,
oiling,
corrosion and
moisture.
Replace damaged, severely carbonised or corroded valves.
Determine cause (see section 7, 'Troubleshooting').
I_WA006_4.fm
2. Clean all sealing surfaces.
62
Maintenance
Removing valves
Note!
Refit all valves with new gaskets and rings only. Only use original
Sauer spare parts. Installing other gaskets may lead to
compressor leaks and damage.
Note!
Never reuse old rings. This may lead to leaks.
1st stage
O-ring
Gasket
1. Install valves and valve covers. Fasten all screwed

connections hand-tight.
I_WA006_4.fm
63
2nd stage
O-ring
Gasket
2. Install valves and valve covers. Fasten all screwed

connections hand-tight.
3. Fasten valve cover nuts tightly. Observe tightening torques
(see section 8.4).
4. Mount air filter and fix with clamp.
5. Attach unions and hose lines to the valve covers.
8.10 Replacing valves

Remove and install valves as described in section 8.9, 'Checking
valves'. Replace complete valve.
Note!
Valves whose service life has expired must be replaced and
disposed of.
Due to material fatigue, we recommend that used valves not be
repaired.
I_WA006_4.fm
64
Maintenance
8.11 Draining the cooling water

Drain plug
1. Block the cooling water inlet and outlet.

2. Remove the hoses for the cooling water inlet and outlet from
the cylinder head.
3. Unscrew the drain plug and drain the cooling water.
8.12 Replacing piston rings, gudgeon pins and

gudgeon pin bearings
1. Drain the cooling water as described in section 8.11, 'Draining
the cooling water'.
2. Remove valve covers and valves as described in section 8.9,
'Checking the valves'.
Note!
If the pistons are not secured during cylinder removal, they will
strike the crankcase.
Dismantling 1. Loosen the unions of the compressed air lines to the

cylinder and condensate separators of 1st and 2nd stage and remove
pipeline.
piston
2. Remove the cooling water connections on the cylinder.
3. Dismantle the inspection hole cover from the crankcase.
I_WA006_4.fm
4. Undo connecting rod bolts of 1st stage and remove together

with lower bearing cap.
65
Note!
Take care that the piston of the 2nd stage is not pushed out of
the liner.
5. Push the piston up into the cylinder, till the connecting rod
upper part is above the crankshaft.
6. Remove the cylinder base nuts below the flange of the
crankcase.
7. Sling the cylinder housing at the two lifting eyes and lift
carefully with a suitable hoist until the connecting rod of the
2nd stage abuts the crankcase from above.
Note!
Take care that the contact surface of the piston is not damaged
while removing.
8. Pull the piston of the 2nd stage above out of the liner together
with the connecting rod and keep in the crankcase.
9. Lift the cylinder housing higher together with the piston of the
1st stage and the connecting rod.
10. Pull the piston of the 1st stage down out of the liner together
with the connecting rod and keep aside.
11. Lift the piston of the 2nd stage together with the connecting
rod up through the liner of the 1st stage.
12. Remove circlips on gudgeon pins and push out gudgeon
pins.
13. Remove all piston rings from the pistons and clean pistons.
Note!
Replace all piston rings with new ones! The following damage
may occur on removal of the piston rings:
• the edges of the piston rings may be damaged on the wearing
edges in the cylinder;
• fine cracks which can lead to material fracture may appear if
the piston rings are bent up repeatedly.
14. Install new piston rings in the respective pistons. Make sure
they are in the correct positions: piston rings with
asymmetrical cross sections are marked on one of the
surfaces with 'TOP'. At the installation this face must face
upwards (see illustration).
I_WA006_4.fm
66
Maintenance
1st stage 2nd stage
TOP
TOP TOP
TOP
Assembling 15. Sequence of assembly is exactly opposite to that of

cylinder and dismantling.
piston 16. Put connecting rod back with sufficient oil and screw on the
bottom part by hand.
Note!
Figures are hammered into the upper and lower sections of the
connecting rods. They must match (see illustration).
7
7
✓ It must be possible for the connecting rod bolts to be fully

screwed in by hand. This is the only way of ensuring that they
are seated correctly on the crankshaft. The connecting rod
must be able to rotate easily on the crankshaft once
tightened.
17. Tighten connecting rod bolts; see tightening torque in section
I_WA006_4.fm
8.4.
67
8.13 Checking pistons and cylinders
1. Remove cylinder heads and valves as described in section
8.9, 'Checking valves'.
2. Remove cylinders and pistons as described in section 8.12,
'Replacing piston rings'.
3. Check cylinders and pistons for scoring and heavy wear and
tear marks. Replace relevant parts.
Note!
If the piston running surface in the cylinder reveals perceptible
wearing edges, the edges must be broken up with a honing
brush or Scotch-Brite abrasive cloth.
Otherwise the edges will damage the new piston rings on
installation of the pistons.
4. Check wear limits as described in section 8.14, 'Wear limits

for cylinder diameters'.
5. Install cylinders and pistons as described in section 8.12,
'Replacing piston rings, gudgeon pins and gudgeon pin
bearings'.
6. Install valves and cylinder heads as described in section 8.9,
'Checking valves'.
8.14 Wear limits for cylinder diameters

1. Measure cylinder and replace if the following wear limits are
exceeded:
Cylinders Wear limit of diameter

1st stage 136.15 mm
2nd stage 60.10 mm

I_WA006_4.fm
68
Maintenance
8.15 Checking the coupling

Visual 1. Remove screw plug from crankcase.
inspection 2. Check the coupling halves through the inspection port.
✓ The teeth on the coupling halves must not be deformed.
3. Replace screw plug.
Screw plug
I_WA006_4.fm
69
8.16 Renewing flexible gear rim
Note!
This applies to Sauer compressors with electric motors.
Renewing 1. Support compressor under the coupling bell housing.

flexible gear rim 2. Remove the electric motor mounting screws.
3. Carefully lift the electric motor using the lifting eyes (see
section 5.1, 'Transport').
4. Carefully pull the electric motor away from the compressor.
5. Replace flexible gear rim.
6. Carefully slide electric motor against the compressor and
tighten the motor mounting screws.
7. Remove support from under the coupling bell housing.
Flexible gear rim
Compressor Motor
8. Reinstall separated connecting lines and pipes.

I_WA006_4.fm
70
Maintenance
8.17 Inspecting the condensate separators

1st stage 2nd stage
1. Remove pipes and check separators for obstructions.
8.18 Overhauling water drain valves

Hexagon nut
1. Unscrew hexagon nut.

2. Carefully lift up plastic threaded part with the screwdriver.
3. Remove coil from armature.
4. Unscrew the four Allen screws.
I_WA006_4.fm
5. Remove upper section of valve.
71
6. Replace following parts:
conical spring, diaphragm and two O-rings.
7. In case of severe soiling: clean nozzle.
8. Position upper section of valve.
9. Tighten the four Allen screws.
10. Place the coil on the armature.
Note!
The coil and the armature must always be dry.
11. Correctly position the plastic threaded part and press onto the
armature.
12. Carefully position hexagon nut by hand and screw on.
13. Lightly tighten hexagon nut using a spanner.
8.19 Cleaning particle trap

1. Block cooling water inlet.
2. Loosen the cap of the particle trap (in front of the cooling
water-control valve) and remove the strainer.
3. Clean the strainer.
4. Fit the strainer back, screw on the cap.
8.20 Checking zinc protection

The zinc protection for the cylinders of the 1st and 2nd stage is
located in the cylinder housing beside the bursting disc.
1. Unscrew the zinc protection and remove loose parts.
2. Check the zinc protection.
Minimum diameter is 24 mm. Regenerate the zinc protection
if the consumption is too high.
3. Fit the zinc protection back with a new sealing ring.
8.21 Bursting disc

1. Unscrew the screws and dismantle the pressure flange
sideways in front on the cylinder housing.
2. Remove bursting disc and sealing ring.
3. Clean sealing surface.
4. Insert new gasket and new bursting disc. Pay attention to the
correct position of the gasket. Fit first the gasket and then the
bursting disc into the cylinder. Observe the tightening torque
I_WA006_4.fm
(see section 8.4).

5. Bolt the pressure flange back.
72
Maintenance
8.22 Checking the cooling water pump

Note!
The cooling water pump is an optional component and is not
supplied as a standard component.
The cooling water pump should be checked as follows in case of

abnormal running sound or leaks:
Removing the 1. Block the cooling water inlet and outlet.

pump 2. Disconnect electrical connection.
3. Remove the drain plug located below on the cylinder of the
2nd stage and drain the cooling water of the compressor.
4. Loosen the flange connections on the cooling water inlet and
outlet of the pump. Remove rings and clean sealing surfaces.
5. Loosen the bolted fastening of the pump at the foot and
remove pump from the console.
Replacing the The floating ring seals are maintainance-free. In case heavy
floating ring leakages are noticed after a long running time, the floating ring
seal is to be replaced as a complete unit.
seals
Note!
Note the diagram of the pump in the Spare Parts Catalogue.
Please refer to the operating instructions provided by the pump
manufacturer.
6. Remove impeller and shaft retaining ring.

7. Pull the entire floating ring seal with the cap out from the
shaft.
Note!
The floating ring seals are delicate elastomers and must not
come into contact with grease or oil.
Avoid touching them with your fingers (use clean gloves or
cloth).
Do not soil or damage floating ring seals.
Moisten the gaskets with low surface tension water to facilitate
assembly.
8. Carefully slide new floating ring seal on to shaft with a rotating

motion.
Note!
The motor bearing should be replaced if the shaft has noticeable
I_WA006_4.fm
play. A possibly damaged pump impeller must likewise be

replaced.
73
Mounting the 1. Assemble the pump back in the reverse sequence. Insert
pump new flange gaskets.
2. Fill pump and suction pipe completely with cooling water.
3. Connect electrical connection.
Checking the Briefly switch on pump motor. The motor must not reach its
direction of operating speed during this. The direction of rotation must be the
same as the one indicated by the arrow on the pump housing.
rotation
I_WA006_4.fm
74
Storage, Preservation – “Lay-up” Procedure
9 Storage, Preservation – “Lay-up”

Procedure
9.1 Safety when storing and
removing
Danger!
The compressor shall only be removed and “laid up” by trained
specialists of the owner. These specialists must be familiar with
the protection devices and regulations before starting the work.
Any work on the electrical installation must be carried out by
qualified electricians only.
In addition, information contained in suppliers’ documentation
must be observed.
75
9.2 Temporary decommissioning
Perform a test run for at least 30 minutes every four weeks.
Additional corrosion prevention measures are not required.
When the Sauer compressor is to be laid up for more than 12
weeks, preservation with a preservation oil is recommended.
When preservation is completed, periodic test runs are not
needed.
Note!
Use one of the preservation oils recommended in Chapter 10
“Lubricant Table” for corrosion protection.
The preservation oil has satisfactory running properties. In an
emergency the machine can be started for a short duration when
filled with preservation oil.
1. Run compressor for approx. 5 minutes with drain valves and

final pressure line open.
Any existing oil/water is removed.
2. Blow out compressor oil and dispose of in an environmentally
safe manner.
3. Fill with about 8 litres of preservation oil.
4. Start compressor and run for approx. 5 minutes with drain
valves and final pressure line open.
5. Stop compressor.
6. Unscrew air filter on the valve cover of the 1st stage.
7. Start compressor and slowly inject approx. 100 cm3 of
preservation oil into the intake fitting.
Oil
Intake fittings
1st stage
8. Wait until oil mist comes out of the final pressure line.
9. Stop compressor.
76
Storage, Preservation – “Lay-up” Procedure
10. Reattach air filter on the valve cover of the 1st stage.
11. If necessary, put up a sign that the compressor was
preserved and taken out of service.
12. If necessary, disconnect mains supply cables.
Putting back into 1. If necessary, connect the mains supply cables.

service 2. Drain preservation oil and pour in compressor oil as
described in Chapter 5.6 “Filling with Oil”.
3. Follow the instructions given in Chapter 6.3 “Initial
Operation”.
77
9.3 Disassembly
Follow these 1. Turn compressor off and disconnect from power supply.
steps for 2. Read the gas pressure display to ensure that the compressor
disassembly: is completely depressurised.
3. Disconnect the mains supply cables.
4. Remove oil and lubricants and dispose of in an
environmentally safe manner.
5. Drain any remaining condensate and dispose of in an
environmentally safe manner.
Disposal
Material/system component Disposal method

Lubricants As hazardous waste
Steel/iron As metal scrap
Electric cables As hazardous waste
Electronic components As scrap electronic waste
Plastics As hazardous waste
78
Lubricant table
10 Lubricant table
Scope The lubricant table applies to all Sauer compressors which are
designed to compress air.
The lubricant table does not apply to
– Sauer compressors designed to compress neutral gasses
– Temperatures outside the 5 to 55 °C range
General For temperatures lying within the 5 to 55 °C range we

recommendation recommend mineral oil meeting the ISO VG 100 viscosity grade.
At minimum, the lubricating oil should correspond to the group
VCL as per DIN 51506 .
Two-stage water-cooled compressors may cause premature
soiling of the valves due to the high compression temperatures
combined with unfavourable ambient conditions or inferior types
of oil. Use another oil in such cases or carry out maintenance at
shorter intervals.
Note!
The recommended types of oil reduce the level of coking in the
compressor valves and the upstream pipe lines and fittings to a
minimum.
Lubricants which are not listed in the lubricant table may only be
used after approval has been given by J.P. SAUER & SOHN.
Otherwise the guarantee is made void.
Please contact our Customer Service when selecting oils not
listed, or if operating conditions differ from those recommended.
Note!
Unless otherwise ordered, Sauer compressors are delivered
without oil.
79
10.1 Lubricating oils
The following mineral oils may be used in Sauer compressors;
Shell Corena P 100 mineral oil is the standard type used to fill and
operate the unit.
Brand Product name Group

Agip Diesel Gamma 30 VCL-100
Dicrea 100 VDL-100
Acer 100 VCL-100
Motor Oil HD 30 SAE 30
Cladium 50 SAE 30
ARAL Kowal M30 VCL-100
AVIA Avilub Verdichteröl VDL-100 VDL-100
BP Energol RC 100 VDL-100
Energol IC-DG 30 VCL-100
Vanellus C3 SAE 30 SAE 30
Aircol PD 100 VDL-100
CHEVRON HD Compressor Oil 100 VDL-100
Delo 1000 Marine 30 SAE 30
Veritas 800 Marine 30 SAE 30
ESSO Rarus 426 VDL-100
Rarus 427 VDL-100
Mobilgard 300 SAE 30
Mobilgard 312 SAE 30
Delvac 1230 SAE 30
Shell Corena P 100 VDL-100
Rimula X 30 SAE 30
Melina S Oil 30 SAE 30
Melina Oil 30 SAE 30
Gadinia Oil 30 SAE 30
TEXACO Compressor Oil EP VDL 100 VDL-100
Regal EP 100 VCL-100
Ursatex 30 SAE 30
Veritas 800 Marine 30 SAE 30
TOTAL Dacnis P 100 VDL-100
Disola M 3015 SAE 30
80
Lubricant table
The following mineral oils may alternatively be used without

restriction in marine applications:
Brand Product name Group

NATO classified O - 278 VDL-120
NATO classified OMD 113 VDL-100
10.2 Preservation oils

The standard oil used by Sauer for compressor preservation is
Mobilarma 524.
Alternatively, the following preservation oils can be used:
Brand Product name

Agip Rustica C SAE 30
ARAL Konit Motoröl SAE 30
AVIA MK 1540 S
BP MEK 20 W-20
DEA Deamot EKM 642 SAE 30
Esso MZK Motorenöl HD 30
Rostschutz MZ 110
Mobil Mobilarma 524
Shell Ensis Motor Oil 30
Note!
The product name may vary by country.
81
11 Spare Parts and Accessories
Note!
Please note the information in Chapter 1 “General” regarding our
genuine Sauer spare parts.
J.P. SAUER & SOHN guarantee the complete spare parts supply
over the entire service life of the Sauer compressor.
Our genuine Sauer spare parts are subject to constant quality
control and further development. They conform to the latest
technical developments.
In addition to genuine Sauer spare parts, our range of supply
includes many accessories for your Sauer compressor as well as
special equipment for your entire compressed air system,
including:
– Fully automatic controls
– Adsorption dryers
– Refrigerant type dryers
– Filters
– Sound-dampening enclosures
– Compressed air vessels and
– fittings
We supply instructions and a maintenance manual for each
accessory.
82
Spare Parts and Accessories
Spare parts The spare parts catalogue is in the Appendix to this Operator
catalogue Manual.
– The required parts can be quickly found with the help of
diagrams, illustrations and lists.
– The spare parts catalogue and Operator Manual are also
available on CD-ROM. This makes it easy to fill out an order
form, print it out and send it in immediately.
To do so, you need the main specifications of your Sauer
compressor from the table below. If the data has not yet been
entered, it can be found on the nameplate affixed to the
crankcase.
Compressor type:
Factory No.:
Year of construction:
You should additionally indicate the number of operating

hours.
83
12 Appendix
This Appendix to the Operator Manual contains
– Form for commissioning certificate
– Form for Return of Goods/Notification of Claim
– Supplier documentation
– Data sheets
84
Appendix
J.P. SAUER & SOHN

Commissioning certificate for compressors Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
E-mail:[email protected]
Purchaser Owner Installation site
Company Company
Street Street
Postcode Postcode
Contact Contact
Phone number Phone number
Customer number
Order number
Compressor type Serial No.
Delivery date Operation hours
Date commissioned
Sauer service engineer Company/name
Company/name
Company/name
Company/name
Check of rotational
Installation of compressor/complete system
direction
Good Faults Compression temp. °C
Ventilation Suction temperature °C
Good Faults Start/stop pressure
Ambient conditions Oil level check
Good Faults Control system check
Voltage? Test run
Good Faults
Vibration behaviour of compressor
Good Faults
Accessories Installation of complete system carried out by:
Compressed air vessel
Refrigerant type dryer
Adsorption dryer Good Faults
Filter
Condensate removal
Operating personnel have received instruction and are familiar with the safety and maintenance requirements.
The maintenance instructions are available to the owner.
The operating company has been advised to use only genuine SAUER & SOHN spare parts.
Notes/faults:
The system has been accepted by the owner. City: Date:
Purchaser Owner Authorised Sauer Service Partner
85
J.P. SAUER & SOHN
Return of goods Maschinenbau GmbH
Notification of claim Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Date: Fax: +49 - 431- 39 40 - 89
E-mail: [email protected]
Manufacturer: Please always complete.
Company Compressor type:
Street
Postcode/City
Customer No. Serial No.:
Location
End customer: Operation hours:
Company
Street Date of fault:
Postcode/City
Customer No. Ambient temperature:
Location
Spare parts Reason for return
To be completed by manufacturer
Designation Quantity Part No. Report on fault

Repair
Checking as customer

service
Goods taken back against
credit note
Short description of fault:
Report
To be completed by
manufacturer only
86
S a u e r
C o m p r e s s o r
Type: WP 100
Spare parts catalogue

WP100_ET_Titel_en_08.fm
WP100_ET_Titel_en_08.fm
Edition: 07 / 2008
Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation
066 069 Compressor WP 100
Page
Ref. No. Assembly
E-
066 069 Compressor WP 100 .......................................................... 6
066 048 Compressor WP 100-100 .................................................... 8
066 049 Crankcase ........................................................................... 12
064 064 Dipstick ................................................................................ 16
066 050 Crankshaft ........................................................................... 18
066 051 Connecting rod 1st stage ..................................................... 20
066 052 Connecting rod 2nd stage .................................................... 22
031 881 Piston 1st stage.................................................................... 24
064 061 Piston 2nd stage................................................................... 26
066 053 Cylinder 1st and 2nd stage................................................... 28
061 822 Zinc protection ..................................................................... 32

066 013 Cylinder 1st and 2nd stage................................................... 34
066 054 Valve cover and valve 1st stage........................................... 36
066 055 Valve cover and valve 2nd stage.......................................... 38
038 157 Concentric valve 2nd stage .................................................. 40
066 056 Air lines................................................................................ 42

063 121 Separator 2nd stage............................................................. 46
037 211 Separator 1st stage.............................................................. 48
066 057 Compressor monitoring and control .................................... 50

066 058 Crankcase vent ................................................................... 52
066 083 Automatic drainage system ................................................. 56
066 085 Cooling water lines .............................................................. 58
066 084 Resilient mounts .................................................................. 62
061 002 Hose line ............................................................................. 64
WP100_ET_en_08.fm
066 103 Cooling water hose line ....................................................... 66

066 340 Resilient mounts with cooling water pump only................... 68
E-3
Page
Ref. No. Assembly
E-
064 018 Temperature monitoring....................................................... 72
038 238 Cooling water pump............................................................. 74
Flexible coupling .................................................................. 78
WP100_ET_en_08.fm
Note:
Explanation of the assemblies in Chapter 3 "Design and
Function" in this Operator Manual.
E-4
WP100_ET_en_08.fm
E-5
1 10, 11 2 4 6, 7, 8
3 5 12
WP100_ET_en_08.fm
E-6
Item No. Ref. No. Designation Quantity

1 066 048 Compressor WP 100-100 1
2 066 083 Automatic drainage system 1
3 066 085 Cooling water lines 1
4 1) Resilient mounts 1
5 064 018 Temperature monitoring 1
6 066 086 Rail 1
7 002 161 Rail 2
8 000 154 Hexagon head screw 2
10 037 321 Motor half coupling 1
11 033 494 Coupling flexible insert 1
12 2) AC motor 1
1)
Resilient mounts order number for WP 100 in connection
with cooling water pump: 066 340, otherwise 066 084
2) The order number for the AC motor is order-specific.
WP100_ET_en_08.fm
E-7
066 048 Compressor WP 100 - 100
8 9
11
7 6
5 1
15
16
3
17
4 2
WP100_ET_en_08.fm
E-8
066 048 Compressor WP 100 - 100
12
10
WP100_ET_en_08.fm
E-9
066 048 Compressor WP 100 - 100
WP100_ET_en_08.fm
E - 10
066 048 Compressor WP 100 - 100

1 066 049 Crankcase 1
2 066 050 Crankshaft 1
3 066 051 Connecting rod 1st stage 1
4 066 052 Connecting rod 2nd stage 1
5 031 881 Piston 1st stage 1
6 064 061 Piston 2nd stage 1
7 066 053 Cylinder 1st and 2nd stage 1
8 066 054 Valve cover and valve 1st stage 1
9 066 055 Valve cover and valve 2nd stage 1

10 066 056 Air lines 1
11 066 057 Compressor monitoring and control 1
12 066 058 Crankcase vent 1
15 000 499 Cap screw 6
16 004 408 Locking pin 4
17 036 345 Compressor half coupling 1
WP100_ET_en_08.fm
E - 11
066 049 Crankcase
31 32 30
14
9
5
20, 24
27
21
22, 28
21, 27
WP100_ET_en_08.fm
E - 12
066 049 Crankcase
21
12
6, 7
19, 25
WP100_ET_en_08.fm
E - 13
066 049 Crankcase
WP100_ET_en_08.fm
E - 14
066 049 Crankcase

1 066 002 Crankcase 1
2 066 019 Bearing housing 1
5 064 137 Flange 1
6 051 883 Crankcase inspection cover 1
7 063 748 Gasket 1
9 066 065 Gasket 1
12 064 064 Dipstick 1
14 000 499 Cap screw 8
19 001 411 Stud screw 8
20 033 717 Stud screw 6
21 001 021 Plug 3
22 030 744 Plug 1
24 001 620 Hexagon nut 6
26 002 161 Washer 6
27 005 029 O-ring 2
28 005 009 O-ring 1
30 007 123 Shaft seal 1
31 030 638 O-ring 1
32 031 024 O-ring 1
WP100_ET_en_08.fm
E - 15
064 064 Dipstick
WP100_ET_en_08.fm
E - 16
064 064 Dipstick

1 037 076 Dipstick 1
3 035 520 O-ring 2
WP100_ET_en_08.fm
E - 17
066 050 Crankshaft
8 1 8
WP100_ET_en_08.fm
E - 18
066 050 Crankshaft

1 066 028 Crankshaft 1
2 064 138 Flywheel 1
4 064 054 Washer 1
8 033 215 Cylindrical roller bearing 2
WP100_ET_en_08.fm
E - 19
066 051 Connecting rod 1st stage
7
1
3
6
8 6
70 Nm 5
2
WP100_ET_en_08.fm
E - 20
066 051 Connecting rod 1st stage

1 066 060 Connecting rod 1
2 066 336 Lubricating pin 1
3 051 139 Connecting rod bearing 1
6 004 486 Dowel pin 2
7 036 107 Small-end bearing 2
81) 053 713 Connecting rod bolt 2
1)
Item 8, Connecting rod bolt 053 713 is part of assembly 066 060.
WP100_ET_en_08.fm
E - 21
066 052 Connecting rod 2nd stage
8 6
70 Nm 5
2
WP100_ET_en_08.fm
E - 22
066 052 Connecting rod 2nd stage

1 066 061 Connecting rod 1
2 066 336 Lubricating pin 1
3 051 139 Connecting rod bearing 1
6 004 486 Dowel pin 2
7 037 156 Small-end bearing 1
81) 053 713 Connecting rod bolt 2
1)
Item 8, Connecting rod bolt 053 713 is part of assembly 066 061.
WP100_ET_en_08.fm
E - 23
031 881 Piston 1st stage
3
4
5
WP100_ET_en_08.fm
E - 24
031 881 Piston 1st stage

1 Piston 1
2 031 883 Gudgeon pin 1
3 012 512 Plain ring 1
4 031 901 Nose ring 1
5 031 902 Oil scraper ring 1
6 002 976 Circlip 2
71) 036 107 Small-end bearing 1
1)
Item 7, Small-end bearing 036 107 is part of assembly 066 051.
WP100_ET_en_08.fm
E - 25
064 061 Piston 2nd stage
7
WP100_ET_en_08.fm
E - 26
064 061 Piston 2nd stage

1 064 129 Piston 1
2 064 074 Gudgeon pin 1
3 031 541 Plain ring 2
4 002 548 Nose ring 1
5 031 542 Oil scraper ring 1
6 002 980 Circlip 2
71) 037 156 Small-end bearing 1
1)
Item 7, Small-end bearing 037 156 is part of assembly 066 052.
WP100_ET_en_08.fm
E - 27
066 053 Cylinder 1st and 2nd stage
1, 9, 10 32 16 3 2, 28
13
28, 33 19, 25 20, 26 28, 34
5, 11
15
6, 12
35, 37
36
35, 37
6, 12
28, 34
5, 11
WP100_ET_en_08.fm
28, 33
E - 28
24 22 17
29
31
21, 27
18
23 29 8 30 7
WP100_ET_en_08.fm
E - 29

1 054 883 Protecting cap 1
2 061 822 Zinc protection 1
3 066 013 Cylinder 1st and 2nd stage 1
5 066 017 Cooler cover 2
6 066 018 Cooler cover 2
7 066 031 Liner 2nd stage 1
8 066 030 Liner 1st stage 1

9 051 530 Gasket 1
10 051 531 Burst disc 1
11 066 070 Gasket 2
12 066 071 Gasket 2
13 066 072 Gasket 1
15 000 504 Cap screw 42
16 000 505 Cap screw 4
17 038 915 Stud screw 8
18 001 534 Stud screw 4
19 001 021 Plug 1
20 030 744 Plug 1
21 030 509 Plug 1
24 002 161 Washer 5
25 005 029 O-ring 1
26 005 009 O-ring 1
27 005 016 O-ring 1
WP100_ET_en_08.fm
E - 30

28 005 023 O-ring 5
29 031 136 O-ring 3
30 004 175 O-ring 1
31 004 181 O-ring 2
32 000 269 Lifting eye bolt 2
33 001 019 Plug 2
34 033 087 Reducing union 2
35 004 949 Fitting 2
36 066 335 Pipe 1
37 038 547 Cutting ring 2
WP100_ET_en_08.fm
E - 31
061 822 Zinc protection
2 3 1
WP100_ET_en_08.fm
E - 32
061 822 Zinc protection

1 061 820 Plug 1
2 061 821 Zinc cartridge 1
3 001 463 Stud screw 1
061 822 Zinc protection is ordered as a complete spare part.

WP100_ET_en_08.fm
E - 33
2
WP100_ET_en_08.fm
E - 34

1 066 024 Cylinder 1
2 066 062 Cooling pipe 44
WP100_ET_en_08.fm
E - 35
066 054 Valve cover and valve 1st stage
4, 7
5 2 1 6
WP100_ET_en_08.fm
E - 36
066 054 Valve cover and valve1st stage

1 066 011 Valve cover 1
2 056 235 O-ring 1
4 030 911 Silencer filter 1
5 037 157 Lamellar valve 1
6 038 158 O-ring 1
71) 033 291 Filter element 1
1)
Item 7, Filter insert 033 291 is part of assembly 030 911.
WP100_ET_en_08.fm
E - 37
066 055 Valve cover and valve 2nd stage
WP100_ET_en_08.fm
E - 38
066 055 Valve cover and valve 2nd stage

1 066 012 Valve cover 1
2 053 398 O-ring 1
4 038 157 Concentric valve 1
5 036 162 O-ring 1
WP100_ET_en_08.fm
E - 39
038 157 Concentric valve 2nd stage
WP100_ET_en_08.fm
E - 40
038 157 Concentric valve 2nd stage

1 031 585 Suction valve plate 1
2 031 586 Delivery valve plate 2
3 031 587 Suction valve spring 2
4 031 588 Sinusoidal compression spring 2
5 038 793 Guide ring 1
WP100_ET_en_08.fm
E - 41
066 056 Air lines
8 10, 16 19
4, 16
12, 15
11, 16 5 18 5, 15 13, 14
WP100_ET_en_08.fm
E - 42
066 056 Air lines
5
17
11, 16
2 1
3
WP100_ET_en_08.fm
E - 43
066 056 Air lines
WP100_ET_en_08.fm
E - 44
066 056 Air lines

1 063 121 Separator 2nd stage 1
2 037 221 Separator 1st stage 1

4 006 227 Fitting 1
5 031 905 Fitting 3
8 036 157 Fitting 2
9 006 319 Fitting 1
10 004 661 Fitting 1
12 030 751 Safety valve 1st stage 1
13 030 752 Safety valve 2nd stage 1

14 005 009 O-ring 1
15 005 016 O-ring 2
16 005 023 O-ring 4
17 066 352 Pipe 1
18 066 094 Pipe 1
19 066 195 Pipe 1
WP100_ET_en_08.fm
E - 45
063 121 Separator 2nd stage
11, 12 9
1
10
3
7
Working pressure 80 bar
Test pressure 160 bar 6
WP100_ET_en_08.fm
E - 46
063 121 Separator 2nd stage

1 063 228 Separator housing 1
2 063 229 Separator head 1
3 062 328 Baffle cone 1
41) 060 342 Fusible plug 1

7 005 029 O-ring 1
8 005 009 O-ring 1
9 036 171 O-ring 1
11 001 007 Plug 1
12 003 496 O-ring 1
1)
121°C / 250 °F
WP100_ET_en_08.fm
E - 47
037 211 Separator 1st stage
3/4“
1/2“
Working pressure: max. 16 bar

WP100_ET_en_08.fm
E - 48
037 211 Separator 1st stage

WP100_ET_en_08.fm
E - 49
066 057 Compressor monitoring and control
5, 8 3, 7, 9 6, 8 5, 8
4, 7, 9
WP100_ET_en_08.fm
E - 50
066 057 Compressor monitoring and control

1 064 326 Double ended stud end 1
3 066 370 Pressure gauge 1st stage 1
4 030 664 Pressure gauge 2nd stage 1

5 035 473 Thermometer compressed air 2
6 030 182 Cooling water angle thermometer 1
7 035 061 O-ring 2
8 005 009 O-ring 3
91) 037 663 Throttle screw 1
1) Item 9, Dowel screw 037 663 is part of assembly 066 370.

WP100_ET_en_08.fm
E - 51
066 058 Crankcase vent
12
WP100_ET_en_08.fm
E - 52
1, 2, 9 10 1, 2, 9 5
3
WP100_ET_en_08.fm
E - 53
WP100_ET_en_08.fm
E - 54

1 037 139 Hose sleeve 2
22) 037 140 Angle piece 2
31) 037 194 Extension piece 1
41) 037 144 Angle piece 1

61) 038 268 T reducer 1
71) 038 407 Pipe nipple joint 1

8 035 824 Filling cover 1
9 035 254 Worm drive hose clip 2
10 034 612 Low-pressure hose 1
12 033 952 Insulation hose 1
1)
Inserted with hemp and Fermit sealing cement.
2)
Inserted with seal tape.
WP100_ET_en_08.fm
E - 55
066 083 Automatic drainage system
10 11 5 1
1, 3, 4, 5, 12
WP100_ET_en_08.fm
E - 56
066 083 Automatic drainage system

1 004 641 Fitting 2
3 006 216 Fitting 1
4 033 961 Stub 1
51) 2) Solenoid valve 2

10 006 187 Elbow fitting 1
11 065 109 Orifice 1
12 030 207 O-ring 1
1)
Specify voltage and frequency for order!
2) The order number for the solenoid valve is order-specific.
WP100_ET_en_08.fm
E - 57
066 085 Cooling water lines
2, 5
WP100_ET_en_08.fm
E - 58
4, 5
3 1
6
WP100_ET_en_08.fm
E - 59
WP100_ET_en_08.fm
E - 60
11) 2) Solenoid valve 1

2 034 469 Particle trap 1
3 037 144 Angle piece 2
4 038 268 T reducer 1
5 038 229 Reducing nipple 2
6 036 967 Pipe fitting 1
7 034 470 Pipe adaptor 3
1)
Specify voltage and frequency for order!
2) The order number for the solenoid valve is order-specific.
Fittings are sealed with hemp and Fermit.

WP100_ET_en_08.fm
E - 61
066 084 Resilient mounts
3, 8 1 9
4, 6, 11 2 5, 6 7
WP100_ET_en_08.fm
E - 62
066 084 Resilient mounts

1 033 222 High pressure hose 1
2 061 002 Hose line 2
3 066 103 Cooling water hose line 2
6 031 149 Anti-vibration resilient mount 8
7 037 172 Mounting plate 4
9 033 489 Non-return valve 1
11 002 203 Washer 5
WP100_ET_en_08.fm
E - 63
061 002 Hose line
1 2
WP100_ET_en_08.fm
E - 64
061 002 Hose line

2 004 698 Fitting 1
WP100_ET_en_08.fm
E - 65
066 103 Cooling water hose line
1 2 1
WP100_ET_en_08.fm
E - 66
066 103 Cooling water hose line

1 004 655 Fitting 2
WP100_ET_en_08.fm
E - 67
066 340 Resilient mounts with cooling water pump only
5, 6, 5, 6, 8,
14 9 7, 15 10 16, 21
14 3, 4, 20 13
17
WP100_ET_en_08.fm
11 19 11 2 12 14
E - 68
27
22, 24, 28
23, 25, 26
WP100_ET_en_08.fm
E - 69
WP100_ET_en_08.fm
E - 70

1 066 442 Support plate 1
2 064 396 Sliding socket 1
3 002 161 Washer 2
4 038 102 Stud screw 2
7 037 293 Flange 1
8 036 614 Flange 1
11 004 661 Fitting 2
12 034 470 Pipe adaptor 1
14 037 144 Angle piece 3
15 030 658 Gasket 1
16 037 441 Gasket 1
17 038 2381) Cooling water pump 1
21 002 166 Washer 4
22 002 153 Washer 4
23 002 156 Washer 6
26 009 253 Threaded rod 2
WP100_ET_en_08.fm
27 037 493 Clamp 1

1) The order number for the cooling water pump is order-specific.
E - 71
064 018 Temperature monitoring
1, 2, 4
WP100_ET_en_08.fm
E - 72
064 018 Temperature monitoring

1 035 468 High air temperature switch 1
2 000 410 Cap screw 2
4 002 144 Washer 2
WP100_ET_en_08.fm
E - 73
038 238 Cooling water pump
1, 2, 3
DN 32
DN 40
Motor terminal box
Cable entry
WP100_ET_en_08.fm
E - 74
038 238 Cooling water pump

1 Cooling water pump 1
2 038 290 Gasket kit 1
31) 038 257 Repair kit 1
1) Repair kit 038 257 can be supplied.
Technical specification
Pump:
Max. working pressure: 10 bar
67 l/min against 19 m water column
Pump capacity:
100 l/min against 18 m water column
Medium: fresh water
Max. working pressure: 55 °C
AC motor1) :
Capacity: 1.1 kW, IP 55
Voltage and frequency: 400/440 V, 50/60 Hz
Max. ambient temperature: 55 °C
1) Also available to customer-specific specifications upon request.

WP100_ET_en_08.fm
E - 75
Flexible coupling
1 2
Compressor Motor
WP100_ET_en_08.fm
E - 76
Flexible coupling
11) 036 345 Compressor half coupling 1
22) 037 321 Motor half coupling 1
33) 033 494 Coupling flexible insert 1
1) Item 1, Compressor half coupling 036 345 is part of assembly 066 048.
2) Item 2, Motor half coupling 037 321 is part of assembly 066 069.
3) Item 3, Coupling flexible insert 033 494 is part of assembly 066 069.
WP100_ET_en_08.fm
E - 77
E - 78
WP100_ET_en_08.fm
Index
Parts List by Ref. No.
Page
Ref. No. Designation Assembly Item
E-
000 119 Hexagon head screw .......................... 066 340 69 28
000 269 Lifting eye bolt ..................................... 066 053 28 32
000 410 Cap screw ........................................... 064 018 72 2
000 499 Cap screw ........................................... 066 048 8 15
000 499 Cap screw ........................................... 066 049 12 14
000 504 Cap screw ........................................... 066 053 28 15
000 505 Cap screw ........................................... 066 053 28 16
001 007 Plug ..................................................... 063 121 46 11
001 019 Plug ..................................................... 066 053 28 33
001 021 Plug ..................................................... 066 049 13 21
001 021 Plug ..................................................... 066 053 28 19
001 411 Stud screw .......................................... 066 049 13 19
001 463 Stud screw .......................................... 061 822 32 3
001 534 Stud screw .......................................... 066 053 29 18
001 620 Hexagon nut ........................................ 066 049 12 24
001 620 Hexagon nut ........................................ 066 053 29 22
001 620 Hexagon nut ........................................ 066 340 68 20
001 621 Hexagon nut ........................................ 066 053 29 23
002 025 Hexagon nut ........................................ 066 340 69 24
WP100_ET_Index_en_08.fm
002 031 Hexagon nut ........................................ 066 049 13 25

002 031 Hexagon nut ........................................ 066 340 69 25
002 051 Hexagon nut ........................................ 066 340 68 6
E - 79
Page
E-
002 093 Hexagon nut ........................................ 066 051 20 5
002 093 Hexagon nut ........................................ 066 052 22 5
002 144 Washer ................................................ 064 018 72 4
002 153 Washer ................................................ 066 340 69 22
002 156 Washer ................................................ 066 340 69 23
002 161 Washer ................................................ 066 049 12 26
002 161 Washer ................................................ 066 053 29 24
002 161 Rail ...................................................... 066 069 6 7
002 161 Washer ................................................ 066 340 68 3
002 166 Washer ................................................ 066 340 68 21
002 203 Washer ................................................ 066 561 62 11
002 548 Nose ring ............................................. 064 061 26 4
002 976 Circlip .................................................. 031 881 24 6
002 980 Circlip .................................................. 064 061 26 6
003 496 O-ring .................................................. 063 121 46 12
004 175 O-ring .................................................. 066 053 29 30
004 181 O-ring .................................................. 066 053 29 31
004 408 Locking pin .......................................... 066 048 8 16
004 486 Dowel pin ............................................. 066 051 20 6
004 486 Dowel pin ............................................. 066 052 22 6
004 641 Fitting .................................................. 066 083 56 1
004 655 Fitting .................................................. 066 103 66 1
004 661 Fitting .................................................. 066 056 42 10
004 661 Fitting .................................................. 066 340 68 11
004 698 Fitting .................................................. 061 002 64 2
004 949 Fitting .................................................. 066 053 28 35
005 009 O-ring .................................................. 063 121 46 8

005 009 O-ring .................................................. 066 049 12 28
005 009 O-ring .................................................. 066 053 28 26
E - 80
Index
Page
E-
005 009 O-ring .................................................. 066 056 42 14
005 009 O-ring .................................................. 066 057 50 8
005 016 O-ring .................................................. 066 053 29 27
005 016 O-ring .................................................. 066 056 42 15
005 023 O-ring .................................................. 066 053 28 28
005 023 O-ring .................................................. 066 056 42, 43 16
005 029 O-ring .................................................. 063 121 46 7
005 029 O-ring .................................................. 066 049 12 27
005 029 O-ring .................................................. 066 053 28 25
006 187 Elbow fitting ......................................... 066 083 56 10
006 216 Fitting .................................................. 066 083 56 3
006 227 Fitting .................................................. 066 056 42 4
006 319 Fitting .................................................. 066 056 42 9
006 380 Reducing union ................................... 066 058 53 5
006 387 Reducing union ................................... 066 056 42, 43 11
006 387 Reducing union ................................... 066 561 62 8
006 390 Reducing union ................................... 063 121 46 6
006 391 Reducing union ................................... 066 340 68 13
007 123 Shaft seal ............................................ 066 049 12 30
009 253 Threaded rod ...................................... 066 340 69 26
012 512 Plain ring ............................................. 031 881 24 3
030 182 Cooling water angle thermometer ....... 066 057 50 6
030 207 O-ring .................................................. 066 083 56 12
030 509 Plug ..................................................... 066 053 29 21
030 638 O-ring .................................................. 066 049 12 31

030 658 Gasket ................................................. 066 340 68 15
030 664 Pressure gauge 2nd stage ................... 066 057 50 4
E - 81
Page
E-
030 744 Plug ..................................................... 066 049 12 22
030 744 Plug ..................................................... 066 053 28 20
030 751 Safety valve 1st stage .......................... 066 056 42 12
030 752 Safety valve 2nd stage ......................... 066 056 42 13

030 911 Silencer filter ........................................ 066 054 36 4
031 024 O-ring .................................................. 066 049 12 32
031 136 O-ring .................................................. 066 053 29 29
031 149 Anti-vibration resilient mount ............... 066 561 62 6
031 541 Plain ring ............................................. 064 061 26 3
031 542 Oil scraper ring .................................... 064 061 26 5
031 585 Suction valve plate .............................. 038 157 40 1
031 586 Delivery valve plate ............................. 038 157 40 2
031 587 Suction valve spring ............................ 038 157 40 3
031 588 Sinusoidal compression spring ............ 038 157 40 4
031 881 Piston 1st stage ................................... 066 048 8 5
031 883 Gudgeon pin ........................................ 031 881 24 2
031 901 Nose ring ............................................. 031 881 24 4
031 902 Oil scraper ring .................................... 031 881 24 5
031 905 Fitting .................................................. 066 056 42, 43 5
033 087 Reducing union ................................... 066 053 28 34
033 215 Cylindrical roller bearing ...................... 066 050 18 8
033 219 High pressure hose ............................. 061 002 64 1
033 291 Filter element ....................................... 030 911 36 7
033 489 Non-return valve .................................. 066 561 62 9
033 494 Coupling flexible insert ........................ 066 069 76 3

033 717 Stud screw ........................................... 066 049 12 20
033 952 Insulation hose .................................... 066 058 52 12
E - 82
Index
Page
E-
033 961 Stub ..................................................... 066 083 56 4
034 469 Particle trap ......................................... 066 085 58 2
034 470 Pipe adaptor ........................................ 066 085 58, 59 7
034 470 Pipe adaptor ........................................ 066 340 68 12
034 612 Low-pressure hose ............................. 066 058 53 10
035 061 O-ring .................................................. 066 057 50 7
035 254 Worm drive hose clip ........................... 066 058 53 9
035 468 High air temperature switch ................ 064 018 72 1
035 473 Compressed air thermometer ............. 066 057 50 5
035 520 O-ring .................................................. 064 064 16 3
035 824 Filling cover ......................................... 066 058 52 8
036 107 Small-end bearing ............................... 066 051 20 7
036 157 Fitting .................................................. 066 056 42 8
036 162 O-ring .................................................. 066 055 38 5
036 171 O-ring .................................................. 063 121 46 9
036 345 Compressor half coupling ................... 066 048 8 17
036 345 Compressor half coupling ................... 066 048 76 1
036 614 Flange ................................................. 066 340 68 8
036 967 Pipe fitting ........................................... 066 085 59 6
037 076 Dipstick ............................................... 064 064 16 1
037 139 Hose sleeve ........................................ 066 058 53 1
037 140 Angle piece ......................................... 066 058 53 2
037 144 Angle piece ......................................... 066 058 52 4
037 144 Angle piece ......................................... 066 085 58, 59 3
037 144 Angle piece ......................................... 066 340 68 14

E - 83
Page
E-
037 157 Lamellar valve ..................................... 066 054 36 5
037 172 Mounting plate ..................................... 066 561 62 7
037 194 Extension piece ................................... 066 058 53 3
037 211 Separator 1st stage .............................. 48
037 221 Separator 1st stage .............................. 066 056 43 2

037 267 Reducing nipple ................................... 066 340 68 9
037 293 Flange ................................................. 066 340 68 7
037 321 Motor half coupling .............................. 066 069 76 2
037 441 Gasket ................................................. 066 340 68 16
037 493 Clamp .................................................. 066 340 69 27
037 663 Throttle screw ...................................... 066 370 50 9
038 102 Stud screw ........................................... 066 340 68 4
038 157 Concentric valve 2nd stage .................. 066 055 38 4
038 158 O-ring .................................................. 066 054 36 6
038 229 Reducing nipple ................................... 066 085 58, 59 5
038 229 Reducing nipple ................................... 066 340 68 10
038 238 Cooling water pump ............................ 066 340 68 17
038 257 Repair kit ............................................. 038 238 74 3
038 268 T reducer ............................................. 066 058 53 6
038 268 T reducer ............................................. 066 085 59 4
038 290 Gasket kit ............................................ 038 238 74 2
038 407 Pipe nipple joint ................................... 066 058 52 7
038 547 Cutting ring .......................................... 066 053 28 37
038 793 Guide ring ............................................ 038 157 40 5

038 915 Stud screw ........................................... 066 053 29 17
051 139 Connecting rod bearing ....................... 066 051 20 3
E - 84
Index
Page
E-
051 530 Gasket ................................................. 066 053 28 9
051 531 Burst disc ............................................ 066 053 28 10
051 883 Crankcase inspection cover ................ 066 049 13 6
053 398 O-ring .................................................. 066 055 38 2
053 713 Connecting rod bolt ............................. 066 060 20 8
054 883 Protecting cap ..................................... 066 053 28 1
056 235 O-ring .................................................. 066 054 36 2
060 342 Fusible plug ......................................... 063 121 46 4
061 002 Hose line ............................................. 066 561 62 2
061 820 Plug ..................................................... 061 822 32 1
061 821 Zinc cartridge ...................................... 061 822 32 2
061 822 Zinc protection .................................... 066 053 28 2
062 328 Baffle cone .......................................... 063 121 46 3
063 121 Separator 2nd stage ............................ 066 056 43 1
063 228 Separator housing ............................... 063 121 46 1
063 229 Separator head ................................... 063 121 46 2
063 748 Gasket ................................................. 066 049 13 7
064 018 Temperature monitoring ...................... 066 069 6 5
064 054 Washer ................................................ 066 050 18 4
064 061 Piston 2nd stage .................................. 066 048 8 6
064 064 Dipstick ............................................... 066 049 13 12
064 074 Gudgeon pin ....................................... 064 061 26 2
064 129 Piston .................................................. 064 061 26 1
064 137 Flange ................................................. 066 049 12 5
064 138 Flywheel .............................................. 066 050 18 2

064 326 Double ended stud end ....................... 066 057 50 1
064 396 Sliding socket ...................................... 066 340 68 2
E - 85
Page
E-
065 109 Orifice .................................................. 066 083 56 11
066 002 Crankcase ........................................... 066 049 13 1
066 011 Valve cover .......................................... 066 054 36 1
066 012 Valve cover .......................................... 066 055 38 1
066 013 Cylinder 1st and 2nd stage ................... 066 053 28 3
066 017 Cooler cover ........................................ 066 053 28 5
066 018 Cooler cover ........................................ 066 053 28 6
066 019 Bearing housing .................................. 066 049 13 2
066 024 Cylinder ............................................... 066 013 34 1
066 028 Crankshaft ........................................... 066 050 18 1
066 030 Liner 1st stage ..................................... 066 053 29 8
066 031 Liner 2nd stage .................................... 066 053 29 7

066 048 Compressor WP 100-100 .................... 066 069 6 1
066 049 Crankcase ........................................... 066 048 8 1
066 050 Crankshaft ........................................... 066 048 8 2
066 051 Connecting rod 1st stage ..................... 066 048 8 3
066 052 Connecting rod 2nd stage .................... 066 048 8 4
066 054 Valve cover and valve 1st stage .......... 066 048 8 8
066 055 Valve cover and valve 2nd stage ......... 066 048 8 9
066 056 Air lines ................................................ 066 048 9 10
066 057 Compressor monitoring and control .... 066 048 8 11
066 058 Crankcase vent ................................... 066 048 9 12
066 060 Connecting rod .................................... 066 051 20 1
066 061 Connecting rod .................................... 066 052 22 1
066 062 Cooling pipe ........................................ 066 013 34 2

066 065 Gasket ................................................. 066 049 12 9
066 070 Gasket ................................................. 066 053 28 11
E - 86
Index
Page
E-
066 071 Gasket ................................................. 066 053 28 12
066 072 Gasket ................................................. 066 053 28 13
066 083 Automatic drainage system ................. 066 069 6 2
066 084 Resilient mounts .................................. 066 069 6 4
066 085 Cooling water lines .............................. 066 069 6 3
066 086 Rail ...................................................... 066 069 6 6
066 094 Pipe ..................................................... 066 056 42 18
066 103 Cooling water hose line ....................... 066 561 62 3
066 195 Pipe ..................................................... 066 056 42 19
066 335 Pipe ..................................................... 066 053 28 36
066 336 Lubricating pin ..................................... 066 051 20 2
066 336 Lubricating pin ..................................... 066 052 22 2
Resilient mounts with cooling
066 340 066 069 6 4
water pump only ..................................
066 352 Pipe ..................................................... 066 056 43 17
066 370 Pressure gauge 1st stage .................... 066 057 50 3
066 442 Support plate ....................................... 066 340 69 1
AC motor ............................................. 066 069 6 12
Cooling water pump ............................ 038 238 74 1
Solenoid valve ..................................... 066 083 56 5
Solenoid valve ..................................... 066 085 59 1
E - 87
Parts List by Designation
Page
E-
AC motor ............................................. 066 069 6 12
066 056 Air lines ................................................ 066 048 9 10
037 140 Angle piece ......................................... 066 058 53 2
037 144 Angle piece ......................................... 066 058 52 4
037 144 Angle piece ......................................... 066 085 58, 59 3
037 144 Angle piece ......................................... 066 340 68 14
031 149 Anti-vibration resilient mount ............... 066 561 62 6
066 083 Automatic drainage system ................. 066 069 6 2
062 328 Baffle cone .......................................... 063 121 46 3
066 019 Bearing housing .................................. 066 049 13 2
051 531 Burst disc ............................................. 066 053 28 10
000 410 Cap screw ........................................... 064 018 72 2
000 499 Cap screw ........................................... 066 048 8 15
000 499 Cap screw ........................................... 066 049 12 14
000 504 Cap screw ........................................... 066 053 28 15
000 505 Cap screw ........................................... 066 053 28 16
002 976 Circlip .................................................. 031 881 24 6
002 980 Circlip .................................................. 064 061 26 6
037 493 Clamp .................................................. 066 340 69 27
035 473 Compressed air thermometer .............. 066 057 50 5
036 345 Compressor half coupling .................... 066 048 8 17
036 345 Compressor half coupling .................... 066 048 76 1
066 057 Compressor monitoring and control .... 066 048 8 11
066 048 Compressor WP 100-100 .................... 066 069 6 1
038 157 Concentric valve 2nd stage .................. 066 055 38 4

066 060 Connecting rod .................................... 066 051 20 1
066 061 Connecting rod .................................... 066 052 22 1
E - 88
Index
Page
E-
066 051 Connecting rod 1st stage ..................... 066 048 8 3
066 052 Connecting rod 2nd stage .................... 066 048 8 4

066 017 Cooler cover ........................................ 066 053 28 5
066 018 Cooler cover ........................................ 066 053 28 6
066 062 Cooling pipe ........................................ 066 013 34 2
030 182 Cooling water angle thermometer ....... 066 057 50 6
066 103 Cooling water hose line ....................... 066 561 62 3
066 085 Cooling water lines .............................. 066 069 6 3
Cooling water pump ............................ 038 238 74 1
038 238 Cooling water pump ............................ 066 340 68 17
066 002 Crankcase ........................................... 066 049 13 1
066 049 Crankcase ........................................... 066 048 8 1
051 883 Crankcase inspection cover ................ 066 049 13 6
066 058 Crankcase vent ................................... 066 048 9 12
066 028 Crankshaft ........................................... 066 050 18 1
066 050 Crankshaft ........................................... 066 048 8 2
038 547 Cutting ring .......................................... 066 053 28 37
066 024 Cylinder ............................................... 066 013 34 1
033 215 Cylindrical roller bearing ..................... 066 050 18 8

031 586 Delivery valve plate ............................. 038 157 40 2
037 076 Dipstick ............................................... 064 064 16 1
E - 89
Page
E-
064 064 Dipstick ................................................ 066 049 13 12
064 326 Double ended stud end ....................... 066 057 50 1
004 486 Dowel pin ............................................. 066 051 20 6
004 486 Dowel pin ............................................. 066 052 22 6
006 187 Elbow fitting ......................................... 066 083 56 10
037 194 Extension piece ................................... 066 058 53 3
035 824 Filling cover ......................................... 066 058 52 8
033 291 Filter element ....................................... 030 911 36 7
004 641 Fitting .................................................. 066 083 56 1
004 655 Fitting .................................................. 066 103 66 1
004 661 Fitting .................................................. 066 056 42 10
004 661 Fitting .................................................. 066 340 68 11
004 698 Fitting .................................................. 061 002 64 2
004 949 Fitting .................................................. 066 053 28 35
006 216 Fitting .................................................. 066 083 56 3
006 227 Fitting .................................................. 066 056 42 4
006 319 Fitting .................................................. 066 056 42 9
031 905 Fitting .................................................. 066 056 42, 43 5
036 157 Fitting .................................................. 066 056 42 8
036 614 Flange ................................................. 066 340 68 8
037 293 Flange ................................................. 066 340 68 7
064 137 Flange ................................................. 066 049 12 5
064 138 Flywheel .............................................. 066 050 18 2
060 342 Fusible plug ......................................... 063 121 46 4
030 658 Gasket ................................................. 066 340 68 15
037 441 Gasket ................................................. 066 340 68 16
051 530 Gasket ................................................. 066 053 28 9

063 748 Gasket ................................................. 066 049 13 7
066 065 Gasket ................................................. 066 049 12 9
E - 90
Index
Page
E-
066 070 Gasket ................................................. 066 053 28 11
066 071 Gasket ................................................. 066 053 28 12
066 072 Gasket ................................................. 066 053 28 13
038 290 Gasket kit ............................................ 038 238 74 2
031 883 Gudgeon pin ....................................... 031 881 24 2
064 074 Gudgeon pin ....................................... 064 061 26 2
038 793 Guide ring ........................................... 038 157 40 5
001 620 Hexagon nut ........................................ 066 049 12 24
001 620 Hexagon nut ........................................ 066 053 29 22
001 620 Hexagon nut ........................................ 066 340 68 20
001 621 Hexagon nut ........................................ 066 053 29 23
002 025 Hexagon nut ........................................ 066 340 69 24
002 031 Hexagon nut ........................................ 066 049 13 25
002 031 Hexagon nut ........................................ 066 340 69 25
002 051 Hexagon nut ........................................ 066 340 68 6
002 093 Hexagon nut ........................................ 066 051 20 5
002 093 Hexagon nut ........................................ 066 052 22 5
035 468 High air temperature switch ................ 064 018 72 1

E - 91
Page
E-
061 002 Hose line ............................................. 066 561 62 2
037 139 Hose sleeve ......................................... 066 058 53 1
033 952 Insulation hose .................................... 066 058 52 12
037 157 Lamellar valve ..................................... 066 054 36 5
000 269 Lifting eye bolt ..................................... 066 053 28 32
066 030 Liner 1st stage ..................................... 066 053 29 8
066 031 Liner 2nd stage .................................... 066 053 29 7

004 408 Locking pin .......................................... 066 048 8 16
034 612 Low-pressure hose .............................. 066 058 53 10
066 336 Lubricating pin ..................................... 066 051 20 2
066 336 Lubricating pin ..................................... 066 052 22 2
037 172 Mounting plate ..................................... 066 561 62 7
033 489 Non-return valve .................................. 066 561 62 9
002 548 Nose ring ............................................. 064 061 26 4
031 901 Nose ring ............................................. 031 881 24 4
031 542 Oil scraper ring .................................... 064 061 26 5
031 902 Oil scraper ring .................................... 031 881 24 5
065 109 Orifice .................................................. 066 083 56 11
003 496 O-ring .................................................. 063 121 46 12
004175 O-ring .................................................. 066 053 29 30
004181 O-ring .................................................. 066 053 29 31
005 009 O-ring .................................................. 063 121 46 8
005 009 O-ring .................................................. 066 049 12 28

005 009 O-ring .................................................. 066 053 28 26
005 009 O-ring .................................................. 066 056 42 14
E - 92
Index
Page
E-
005 009 O-ring .................................................. 066 057 50 8
005 016 O-ring .................................................. 066 053 29 27
005 016 O-ring .................................................. 066 056 42 15
005 023 O-ring .................................................. 066 053 28 28
005 023 O-ring .................................................. 066 056 42, 43 16
005 029 O-ring .................................................. 063 121 46 7
005 029 O-ring .................................................. 066 049 12 27
005 029 O-ring .................................................. 066 053 28 25
030 207 O-ring .................................................. 066 083 56 12
030 638 O-ring .................................................. 066 049 12 31
031 024 O-ring .................................................. 066 049 12 32
031 136 O-ring .................................................. 066 053 29 29
035 061 O-ring .................................................. 066 057 50 7
035 520 O-ring .................................................. 064 064 16 3
036 162 O-ring .................................................. 066 055 38 5
036 171 O-ring .................................................. 063 121 46 9
038 158 O-ring .................................................. 066 054 36 6
053 398 O-ring .................................................. 066 055 38 2
056 235 O-ring .................................................. 066 054 36 2
034 469 Particle trap ......................................... 066 085 58 2
066 094 Pipe ..................................................... 066 056 42 18
066 195 Pipe ..................................................... 066 056 42 19
066 335 Pipe ..................................................... 066 053 28 36
066 352 Pipe ..................................................... 066 056 43 17
034 470 Pipe adaptor ........................................ 066 085 58, 59 7
034 470 Pipe adaptor ........................................ 066 340 68 12
036 967 Pipe fitting ........................................... 066 085 59 6

038 407 Pipe nipple joint ................................... 066 058 52 7
064 129 Piston .................................................. 064 061 26 1
E - 93
Page
E-
031 881 Piston 1st stage ................................... 066 048 8 5
064 061 Piston 2nd stage .................................. 066 048 8 6

012 512 Plain ring ............................................. 031 881 24 3
031 541 Plain ring ............................................. 064 061 26 3
001 007 Plug ..................................................... 063 121 46 11
001 019 Plug ..................................................... 066 053 28 33
001 021 Plug ..................................................... 066 049 13 21
001 021 Plug ..................................................... 066 053 28 19
030 509 Plug ..................................................... 066 053 29 21
030 744 Plug ..................................................... 066 049 12 22
030 744 Plug ..................................................... 066 053 28 20
061 820 Plug ..................................................... 061 822 32 1
066 370 Pressure gauge 1st stage .................... 066 057 50 3
030 664 Pressure gauge 2nd stage ................... 066 057 50 4

054 883 Protecting cap ..................................... 066 053 28 1
002 161 Rail ...................................................... 066 069 6 7
066 086 Rail ...................................................... 066 069 6 6
037 267 Reducing nipple ................................... 066 340 68 9
038 229 Reducing nipple ................................... 066 085 58, 59 5
038 229 Reducing nipple ................................... 066 340 68 10
006 380 Reducing union ................................... 066 058 53 5
006 387 Reducing union ................................... 066 056 42, 43 11
006 387 Reducing union ................................... 066 561 62 8
006 390 Reducing union ................................... 063 121 46 6
006 391 Reducing union ................................... 066 340 68 13
Reducing union ................................... 066 053 28 34
033 087
038 257 Repair kit ............................................. 038 238 74 3

066 084 Resilient mounts .................................. 066 069 6 4
066 340 Resilient mounts with cooling
E - 94
Index
Page
E-
06
water pump 6
6 4
only 06
9
030 751 Safety valve 1st stage ......................... 066 056 42 12
030 752 Safety valve 2nd stage ........................ 066 056 42 13
037 211 Separator 1st stage ............................. 48
037 221 Separator 1st stage ............................. 066 056 43 2
063 121 Separator 2nd stage ............................ 066 056 43 1

063 229 Separator head ................................... 063 121 46 2
063 228 Separator housing ............................... 063 121 46 1
007 123 Shaft seal ............................................ 066 049 12 30
030 911 Silencer filter ....................................... 066 054 36 4
031 588 Sinusoidal compression spring ........... 038 157 40 4
064 396 Sliding socket ...................................... 066 340 68 2
Solenoid valve ..................................... 066 083 56 5
Solenoid valve ..................................... 066 085 59 1
033 961 Stub ..................................................... 066 083 56 4
001 411 Stud screw .......................................... 066 049 13 19
001 463 Stud screw .......................................... 061 822 32 3
001 534 Stud screw .......................................... 066 053 29 18
033 717 Stud screw .......................................... 066 049 12 20
038 102 Stud screw .......................................... 066 340 68 4

038 915 Stud screw .......................................... 066 053 29 17
031 585 Suction valve plate .............................. 038 157 40 1
031 587 Suction valve spring ............................ 038 157 40 3
E - 95
Page
E-
066 442 Support plate ....................................... 066 340 69 1
038 268 T reducer ............................................. 066 058 53 6
038 268 T reducer ............................................. 066 085 59 4
064 018 Temperature monitoring ...................... 066 069 6 5
009 253 Threaded rod ....................................... 066 340 69 26
037 663 Throttle screw ...................................... 066 370 50 9
066 011 Valve cover .......................................... 066 054 36 1
066 012 Valve cover .......................................... 066 055 38 1
066 054 Valve cover and valve 1st stage .......... 066 048 8 8
066 055 Valve cover and valve 2nd stage ......... 066 048 8 9
002 144 Washer ................................................ 064 018 72 4
002 153 Washer ................................................ 066 340 69 22
002 156 Washer ................................................ 066 340 69 23
002 161 Washer ................................................ 066 049 12 26
002 161 Washer ................................................ 066 053 29 24
002 161 Washer ................................................ 066 340 68 3
002 166 Washer ................................................ 066 340 68 21
002 203 Washer ................................................ 066 561 62 11
064 054 Washer ................................................ 066 050 18 4
035 254 Worm drive hose clip ........................... 066 058 53 9
061 821 Zinc cartridge ....................................... 061 822 32 2
E - 96

Manual Compressor de Ar Principal WP100 - BA - en - 08b

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S a u e r

3 Design and Function. . . . . . . . . . . . . . . . . . . . . . . . . 20

7 Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . .52

11 Spare Parts and Accessories. . . . . . . . . . . . . . . . . . 82

1.3 Warranty and Liability

1.5 J.P. SAUER & SOHN Customer Service

J.P. SAUER & SOHN Maschinenbau GmbH

Instructions Individual instructions or multiple instructions requiring action but

Instructions to be carried out in a certain sequence are

Results of actions carried out are denoted by a tick mark.

The control light is on.

Safetyinstruc- Safety and warning instructions are presented pictorially with

2.2 Unauthorised modification

2.4 Safety Warnings on the Machine

The Sauer compressor with an EC Manufacturer's Declaration or

Safety label Meaning Safety label Meaning

High voltage! Danger Read Operator

Location of safety markings

Safety valves Each compression stage of the Sauer compressor is equipped

2.6 Noise protection

2.7 Waste disposal

2.9 Personal protective equipment

Cooling water Cooling water

1st stage 2nd stage

Compressor Driven by an AC motor drive, the Sauer compressor is controlled

Condensate Oil/water condensate that collects during compression and inter-

Item Designation Display

3.4 Indicators and operating elements on the

On the front of the compressor control, the following indicators

Maximum working pressure 30 bar

Set pressures for safety valves:

Oil sump capacity 9l

Oil level switch (option):

Operating current 0.5 A

Final pressure sensor (option):

Maximum permissible entry pressure at 5 bar without cooling water pump

Weight and dimensions See installation drawing

M Drive Solenoid valve Suction filter

Compressor Safety valve Inter-,

Transport The Sauer compressor must be transported using a forklift truck

Lifting eye bolt

5.2 Storage before Installation

For proper installation follow the installation instructions and

Correct ventilation Incorrect ventilation

– At room temperatures below +5 °C the room must be heated

The cooling water spaces are automatically kept vented through

Seawater can be used for cooling if desired, but according to its

5.4 Connecting the compressor

Cooling water Cooling water

Correct connection Incorrect connection

Item Designation Type Function

pump (option) not self-priming

Oil fill cap

1. Unscrew the oil fill cap (red).

5.6 Checks to be carried out after installation and

6.2 Operating modes

7. Checking the direction of rotation of the cooling water pump

Test run 1. Switch the power supply on.

Checks • Inspect connections, pipes and electric cables for damage.